EP0013125B1 - Verfahren zur Herstellung punktgebundener Stoffe - Google Patents

Verfahren zur Herstellung punktgebundener Stoffe Download PDF

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Publication number
EP0013125B1
EP0013125B1 EP79302958A EP79302958A EP0013125B1 EP 0013125 B1 EP0013125 B1 EP 0013125B1 EP 79302958 A EP79302958 A EP 79302958A EP 79302958 A EP79302958 A EP 79302958A EP 0013125 B1 EP0013125 B1 EP 0013125B1
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EP
European Patent Office
Prior art keywords
web
fabric
liquid
fibers
bonded
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Expired
Application number
EP79302958A
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English (en)
French (fr)
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EP0013125A1 (de
Inventor
Virginia Caroline Menikheim
Bernard Silverman
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Monsanto Co
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Monsanto Co
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres

Definitions

  • This invention relates to processes for bonding non-woven webs of organic fibers to form nonwoven fabrics. More specifically, the invention relates to such processes wherein the web is preferentially bonded in spaced, discrete areas.
  • Nonwoven fabrics and numerous uses thereof are well known to those skilled in the art. Such fabrics are prepared by forming a web of continuous filament and/or staple fibers and bonding the fibers at points of fiber-to-fiber contact to provide a fabric of requisite strength.
  • non-woven web Depending on the intended use of the non- woven web, satisfactory bonding in some instances be accomplished mechanically, e.g., by needle punching or interlacing of the fibers or by application of adhesives to the fibrous web.
  • mechanically e.g., by needle punching or interlacing of the fibers or by application of adhesives to the fibrous web.
  • bonding of this type is in some instances obtained by the application of heat to soften or plasticize the fibers and render them cohesive.
  • the web can be subjected to mechanical compression to increase contact of the thermally softened fibers and provide bonds of required strength.
  • nonwoven fabric When web fibers are bonded at essentially all points of fiber-to-fiber contact, for example, by overall compression of the web in the presence of heat, the resultant nonwoven fabric tends to be stiff and boardy and characterized by low elongation and tear resistance. That is, such overall bonded fabrics are frequently more similar to paper than to conventional textile fabrics.
  • nonwoven "point-bonded" fabrics In order to more closely simulate the properties of conventional textiles, nonwoven "point-bonded" fabrics have been prepared by processes tending to effect preferential bonding in spaced, discrete areas (primary bond sites). In order to provide point-bonded nonwoven fabrics of adequate strength, it is generally necessary that bonding of the web in the primary bond sites be accompanied by mechanical compression.
  • the compression means are generally heated sufficiently to effect thermal bonding.
  • bonding is not limited to the primary bond sites produced in the areas compressed. Varying degrees of secondary or “tack” bonding are generally observed between the primary bond sites. Such "tack” bonding probably results from the fact that techniques employed for preparing point-bonded non- woven fabrics expose areas of the web between the areas being compressed to heat sufficient to effect some softening and tack bonding of fibers at points of contact.
  • the strength and number of the tack bonds formed may vary widely with the properties of the fiber utilized in the web as well as the conditions employed for effecting bonding in the primary bond sites. Desired fabric properties such as softness are progressively impaired as the degree of tack bonding is increased. There is, therefore, a need in the art for processes capable of providing softer non- woven fabrics.
  • the process of the invention is one for making point-bonded nonwoven fabrics by simultaneously heating and compressing spaced discrete areas of a nonwoven web to effect thermal bonding of fibers in such areas, there being incorporated in said web an attenuating liquid in sufficient quantity that under the conditions of heat and compression employed, a point-bonded fabric is obtained which has a bending modulus at least 20% lower than that of a fabric prepared without the use of said attenuating liquid under otherwise equivalent conditions.
  • thermoly bondable organic fibers is used herein in the specification and claims to denote fibers which can be bonded at points of fiber-to-fiber contact by the application of heat and compression.
  • thermoplastic polymer essentially any thermoplastic polymer can be utilized.
  • the fibers may be in the form of continuous filaments or staples or mixtures thereof.
  • bondable fibers suitable for use in the practice of this invention include polyamide fibers such as nylon 6 and nylon 66; and polyester polymer fibers.
  • Composite fibers such as fibers having a sheath of one polymer and a core of another polymer or side-by-side poly- component fibers can be utilized.
  • multicomponent fibers it is not essential that all polymer components thereof be bondable under the process conditions hereinafter described. It is sufficient that such multicomponent fibers have bondable surface portions. If desired, the fibers can be crimped or textured to provide elasticity or other desired characteristics to the finished fabric.
  • the thermally bondable fibers are processed in the form of nonwoven webs.
  • the nonwoven webs of bondable organic fibers may be composed entirely of bondable fibers or, alternatively, may consist of bondable fibers interspersed with other fibers.
  • the art of preparing nonwoven webs is well understood and the manner of web formation is not critical. Generally webs are formed by deposition of fibers on a moving belt in either random or aligned orientation to provide a web having a weight of from 4 to 400 grams per square meter, preferably 10 to 150 grams per square meter. Particularly useful methods for web formation are disclosed in United States Patent No. 3,542,615.
  • a selected quantity of attenuating liquid is applied to the web and the web is simultaneously heated and compressed in spaced discrete areas to effect bonding of the fibers in such areas.
  • the attenuating liquid can be any liquid whose presence in the web in quantities of 1000% or less of the web weight does not, under the bonding conditions employed, provide a fabric having higher strip tenacity (strength) than would be obtained in the absence of such liquid under otherwise equivalent conditions and which provides a fabric having at least a 20% lower bending modulus than that of a fabric obtained in the absence of such liquid under otherwise identical conditions.
  • a key element of the present invention is this unexpected discovery that utilization of an attenuating liquid in sufficient quantity will provide a reduction in fabric bending modulus (i.e., an increase in fabric "softness") as compared to that of fabrics prepared using no liquid under otherwise equivalent conditions.
  • a quantity is employed to reduce bending modulus by at least 20%.
  • the actual amount of attenuating liquid used may be any quantity sufficient to effect such reduction. Generally, there is no theoretical objection to use of very large quantities of liquid.
  • the amount of liquid be chosen such that in addition to reducing bending modulus by at least 20% a higher ratio of strip tenacity to bending modulus (as compared to that obtained using no liquid) is obtained. That is, the maximum quantity utilized is preferably chosen so as not to reduce fabric strength disproportionately to improvements in softness obtained.
  • a particular liquid will function as an attenuating bonding liquid will depend on the nature of the nonwoven web to be bonded, the properties of the fibers constituting the web and the manner in which the web is heated and compressed. Therefore, it is not practical to exhaustively list all combinations of liquids, fibrous webs and conditions of temperature and compression suitable for the practice of the present invention. For example, water will effectively improve the bonding of a web of nylon fibers highly compressed in spaced discrete areas at temperatures below that required to cohesively soften an otherwise identical dry web. Thus, under such conditions water is considered a bonding agent rather than an attenuating liquid. However, under low compressive force and temperatures sufficiently high to effect thermal bonding, water may function as an attenuating liquid. The effectiveness of a particular liquid as an attenuating liquid under given bonding conditions can readily be determined by routine tests.
  • Attenuating liquids provide softening by limiting (for example by evaporative cooling, heat capacity, etc.) the temperatures attained in the web in areas not being simultaneously heated and compressed as hereinafter described.
  • the heat attenuation provided by the liquid is believed to limit or prevent tack bonding outside the discrete, spaced areas which are heated and compressed, thereby providing a softer fabric.
  • preference may be given to those which have relatively low boiling points as compared to fiber softening points and/or those having high heat capacities.
  • any liquid which is not a bonding agent and has a boiling point below the fiber softening point will be an effective attenuating liquid.
  • liquids contemplated to be suitable attenuating liquids for polyamide fibers include water and hexane; examples of suitable attenuating liquids for polyester fibers include water and carbon tetrachloride.
  • the non- woven web containing the attenuating liquid is simultaneously heated and compressed in spaced, discrete areas (points) to effect fiber bonding in such areas thereby forming the web into a point-bonded fabric.
  • Simultaneous heating and compression of the web in spaced, discrete areas can readily be accomplished by compressing the webs between a pair of compressing means such as rolls or platens at least one of which compression means is heated. Further, one or both of the compression means wi!! have bosses or a land and groove design or combinations thereof such that compression of the web will be effected in spaced discrete areas rather than overall. In order to provide adequate overall physical properties it is generally desirable that from 2% to 80%, preferably 3% to 50%, most preferably 5% to 30%, of the total surface area of the web be subjected to compression. Further, the number of spaced, discrete bond sites per square centimeter generally should be from 1 to 250, preferably from 16 to 64.
  • the compressive force, the temperature, and the time of exposure of the web to compression and heating will depend on the nature and quantity of the attenuating liquid utilized and the nature of the fibers being processed. Therefore, for a particular nonwoven web and a particular attenuating liquid, the compressive force, the temperature, and the time of exposure of the web to the compressive force and heating will be correlated to effect bonding of the web fibers in the heated, compressed areas.
  • the heating and compression will be correlated to effect a degree of bonding sufficient to provide a wash stable fabric as hereinafter defined.
  • increases in bonding will be observed with increased temperature until a temperature is attained beyond which further increases will have little, if any, beneficial effect.
  • the heat attenuation characteristics of the liquid may not be adequate to provide requisite improvements in fabric softness.
  • the use of increasing quantities of attenuating liquid may require increased compressive force and/or temperature to provide wash stable fabrics.
  • the optimum correlation of temperature and compressive force can, of course, be empirically determined by routine tests.
  • Strip Tenacity is used as an indicator of fabric strength and is determined by dividing the breaking load of cut fabric strip (as determined by American Society of Testing Materials procedure D-1682-84) by the fabric basis weight. Strip Tenacity is expressed as g/cm/g/m 2 . Values reported are an average of tenacities in the machine and transverse directions of the fabric. (The machine direction corresponds to the direction of feed to the heating -and compressing means and the transverse direction is the planar direction at a right angle thereto).
  • Bending Modulus is used as a measure of fabric softness and is determined in accordance with techniques as described in U.S. Patent 3,613,445.
  • a test fabric is forced vertically downward through a slot at a constant speed.
  • a signal is generated in proportional response to the load incurred in moving the fabric into and through the slot.
  • a load-extension curve is generated by plotting the signal as a function of the distance.
  • Hand, drape and bending modulus are determined by analyzing the load-extension curve. Hand is represented by the maximum point on the load-extension curve.
  • Drape is represented by the slope of the load-deflection curve and bending modulus is determined by dividing the drape value by the cube of fabric thickness.
  • Bending Modulus as determined on a 10.6x 10.6 cm sample, is expressed in gm/cm 4 and values reported are an average of fabric face up and face down machine and transverse direction measurements.
  • Wash stability is determined as follows: Non- woven fabric samples are mixed with at least 10 pieces of hemmed cotton sheeting each measuring about 91 cmx91 cm. The number and size of the nonwoven fabric samples are subject to the following constraints:
  • the total weight of the cotton sheeting plus the nonwoven samples should not exceed about 1.8 kg. (These constraints assure comparable results).
  • the load is washed in a Kenmore Model 76431100 washing machine (marketed by Sears Roebuck Et Co.) using the "normal" cycle (14 min.) "Hi” water level (55 !), Hot Wash, Warm Rinse (water temperatures of 60°C. ⁇ 3°, 49°C. ⁇ 3°) and 90 g of American Association of Textile Colorists and Chemists Standard Detergent 124.
  • the wash load is then dried in a Kenmore electric dryer, Model 6308603 (marketed by Sears, Roebuck and Co.) for at least 30 minutes (or longer if required to dry the entire load).
  • the test specimens are then evaluated by visual observation to determine the number of pills formed.
  • a pill is a visually discernible (usually roughly spherical) tangle of fiber, or fiber plus extraneous material, extending above the surface of a fabric and connected to the body of the fabric by one or more filaments.
  • a fabric is considered to fail the test when 5 or more pills are observed in any 929 square centimeters surface area or when more severe physical deterioration is visually discernible. Fabrics passing the above test are considered "wash-stable".
  • the pills are predominantly formed by fibers which were not bonded in the process of which, in test procedure, were freed from bond sites.
  • the degree of pilling provides a measure of the efficacy of the process for forming bonds and a measure of the resulting bond integrity.
  • more severe fabric deviation than pilling, e.g., complete disintegration may be observed.
  • fabrics which do not pass the test even if not totally or partially disintegrated in the test) will not withstand substantial physical stress or repeated washings without excessive deterioration.
  • Nonwoven webs composed of continuous filament, 24% crystalline polyethylenetereph- thalate fibers and having web weights of 5 gms/meter 2 and wetted with water to the add-on percentages shown in Table 1 below are simultaneously heated and compressed in spaced discrete areas by passage at a speed of .6 meters/minute between a pair of metal rolls.
  • One roll is smooth while the other has 28 square boss sites/cm 2 aligned in a square pattern covering about 18% of the surface area of the roll.
  • the pressure at the roll nip is calculated as 65.0 kg/cm (assuming all pressure to be applied only to the boss sites). Both rolls are heated to a temperature of 230°C. Properties of the fabrics obtained are shown in Table 1 below.
  • test 3 is anamolous and may reflect inaccurate measuring or sampling
  • test 3 shows that the use of water as described enables the preparation of point-bonded polyester fabrics of improved softness.
  • Nonwoven webs composed of continuous filament crystalline polyethylene terephthalate fibers are passed (either wet with about 1000% add-on carbon tetrachloride or dry) through the nip of a pair of rolls at a speed of 6 meters/min.
  • Each roll bears a helical land and groove pattern (508 micron land width; 1270 micron groove width) with the lands and grooves disposed at 45° angles to the roll axis and cooperating to produce a pattern of diamond shaped depressions covering about 8% of the web surface.
  • the rolls exert a nip pressure of 130 kg/cm (calculated as in Example 1).
  • Nonwoven webs of continuous filament nylon 6,6 were processed at 225°C. with and without about 700% add-on hexane using the same roll pattern and presusre as in Example II.
  • the use of hexane provided a fabric having about a 40% lower bending modulus and a substantially higher ratio of strip tenacity to bending modulus than that obtained without the use of hexane.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Claims (9)

1. Verfahren zum Herstellen von punktweise gebundenen, nichtgewebten Stoffen durch gleichzeitiges Erhitzen und Pressen diskreter Bereiche einer nichtgewebten Gutbahn zum Herbeiführen einer thermischen Bindung von Fasern in solchen Bereichen, bei welchem eine abschwächende Flüssigkeit in einer solchen Menge in der Gutbahn enthalten ist, daß man unter den angewendeten Bedingungen von Hitze und Druck einen punktweise gebundenen Stoff erhält, dessen Beigemodul um wenigstens 20% niedriger ist als der eines ohne die Verwendung der abschwächenden Flüssigkeit unter sonst gleichartigen Bedingungen hergestellten Stoffs.
2. Verfahren nach Anspruch 1, in welchem die abschwächende Flüssigkeit eine Flüssigkeit ist, welche unter den gegebenen Bedingungen kein Bindemittel für die Fasern darstellt und deren Siedepunkt unterhalb des Erweichungspunkts der Fasern liegt.
3. Verfahren nach Anspruch 1 oder 2, in welchem die Menge der abschwächenden Flüssigkeit so gewählt ist, daß der hergestellte nichtgewebte Stoff ein höheres Verhältnis von Stripfestigkeit zu Biegemodul hat als ein ohne die Verwendung von Flüssigkeit unter sonst gleichartigien Bedingungen hergestellter Stoff.
4. Verfahren nach einem der Ansprüche 1 bis 3, in welchem die Menge der Flüssigkeit, die Temperatur, die Preßkraft und die Zeitspanne, während welcher die Gutbahn diesen ausgesetzt ist, derart aufeinander abgestimmt sind, daß man einen waschfesten, punktweise gebundenen, nichtgewebten Stoff erhält.
5. Verfahren nach einem der Ansprüche 1 bis 4, in welchem das gleichzeitige Erhitzen und Pressen der Gutbahn erfolgt, indem man die Gutbahn unter Kompression durch den Spalt zwischen zwei Walzen hindurchführt, von denen wenigstens eine beheizt ist und von denen wenigstens eine ein Muster von Oberflächenerhebungen hat, welches im Zusammenwirken mit der gegenüberliegenden Oberfläche der anderen Walze eine Pressung der Gutbahn in einzelnen, diskreten Bereichen bewirkt.
6. Verfahren nach Anspruch 5, in welchem die Oberflächen der Walzen so ausgebildet sind, daß der durch das Pressen hergestellte, punktweise gebundene Stoff ein Muster von etwa 16 bis 64 diskreten Bindungspunkten pro Quadratzentimeter aufweist, welche zwischen 3% und 50% der Oberfläche des Stoffs abdecken.
7. Verfahren nach Anspruch 6, in welchem eine der Walzen mit punktförmigen Erhebungen versehen ist, welche so bemessen und angeordnet sind, daß ein Stoff mit dem genannten Muster entsteht.
8. Verfahren nach Anspruch 6, in welchem jede Walze ein Oberflächenmuster aus entlang Schraubenlinien verlaufenden Erhebungen und Rillen aufweist, welches mit dem aus Erhebungen und Rillen gebildeten Oberflächenmuster der gegenüberliegenden Walze zusammenwirkt, so daß ein Stoff mit dem genannten Muster entsteht.
9. Verfahren nach einem der Ansprüche 1 bis 8, in welchem die Gutbahn fortlaufende Polyester-Elementarfasern enthält und die abschwächende Flüssigkeit Wasser ist.
EP79302958A 1978-12-21 1979-12-19 Verfahren zur Herstellung punktgebundener Stoffe Expired EP0013125B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US97218678A 1978-12-21 1978-12-21
US972186 1992-11-04

Publications (2)

Publication Number Publication Date
EP0013125A1 EP0013125A1 (de) 1980-07-09
EP0013125B1 true EP0013125B1 (de) 1983-06-08

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ID=25519310

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EP79302958A Expired EP0013125B1 (de) 1978-12-21 1979-12-19 Verfahren zur Herstellung punktgebundener Stoffe

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EP (1) EP0013125B1 (de)
JP (1) JPS5584462A (de)
BR (1) BR7908369A (de)
CA (1) CA1145213A (de)
DE (1) DE2965649D1 (de)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
CA2092604A1 (en) 1992-11-12 1994-05-13 Richard Swee-Chye Yeo Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US5482772A (en) 1992-12-28 1996-01-09 Kimberly-Clark Corporation Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB618178A (en) * 1943-02-03 1949-02-17 British Celanese Improvements in the production of fibrous heat insulating materials
US3365354A (en) * 1963-08-07 1968-01-23 Johnson & Johnson Overlay sheet and process for making the same
DE2049943B2 (de) * 1970-10-10 1978-07-20 Bayer Ag, 5090 Leverkusen Verfahren zur Herstellung van verfestigten Polyamid-Vliesstoffen
DE2056542A1 (en) * 1970-11-17 1972-05-18 Bonded fibre fleece prodn useful as a - substitute leather
US3996404A (en) * 1974-07-30 1976-12-07 Japan Vilene Company Ltd. Conjugate polycarbonate fibers and fibrous sheets made thereof
NL7703952A (nl) * 1976-04-15 1977-10-18 Monsanto Co Werkwijze voor het binden of hechten van een niet geweven baan of vel, alsmede het produkt van deze werkwijze.
JPS53126366A (en) * 1977-04-05 1978-11-04 Monsanto Co Adhering of nonnwoven web

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Publication number Publication date
DE2965649D1 (en) 1983-07-14
CA1145213A (en) 1983-04-26
EP0013125A1 (de) 1980-07-09
BR7908369A (pt) 1980-07-22
JPS5584462A (en) 1980-06-25

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Inventor name: SILVERMAN, BERNARD

Inventor name: MENIKHEIM, VIRGINIA CAROLINE

PLAB Opposition data, opponent's data or that of the opponent's representative modified

Free format text: ORIGINAL CODE: 0009299OPPO

R26D Opposition deemed not to have been filed (corrected)

Opponent name: J. H. BENECKE AG

Effective date: 19840319