EP0171807B1 - Etoffe non-tissée entremêlée contenant des fibres thermoplastiques en surface et son procédé de fabrication - Google Patents
Etoffe non-tissée entremêlée contenant des fibres thermoplastiques en surface et son procédé de fabrication Download PDFInfo
- Publication number
- EP0171807B1 EP0171807B1 EP85110212A EP85110212A EP0171807B1 EP 0171807 B1 EP0171807 B1 EP 0171807B1 EP 85110212 A EP85110212 A EP 85110212A EP 85110212 A EP85110212 A EP 85110212A EP 0171807 B1 EP0171807 B1 EP 0171807B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- fusible
- base
- entangled
- fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 287
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 15
- 229920001169 thermoplastic Polymers 0.000 title abstract description 12
- 239000004416 thermosoftening plastic Substances 0.000 title abstract description 12
- 238000004519 manufacturing process Methods 0.000 title description 2
- 238000002844 melting Methods 0.000 claims abstract description 37
- 230000008018 melting Effects 0.000 claims abstract description 37
- 239000004744 fabric Substances 0.000 claims description 72
- 239000010410 layer Substances 0.000 claims description 49
- 229920000728 polyester Polymers 0.000 claims description 24
- -1 polyethylene Polymers 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 13
- 238000005299 abrasion Methods 0.000 claims description 10
- 239000004698 Polyethylene Substances 0.000 claims description 9
- 229920000573 polyethylene Polymers 0.000 claims description 9
- 239000012530 fluid Substances 0.000 claims description 6
- 239000002344 surface layer Substances 0.000 claims description 4
- 238000009986 fabric formation Methods 0.000 claims 2
- 239000000203 mixture Substances 0.000 abstract description 2
- 239000011162 core material Substances 0.000 description 14
- 230000007246 mechanism Effects 0.000 description 9
- 229920000139 polyethylene terephthalate Polymers 0.000 description 7
- 239000005020 polyethylene terephthalate Substances 0.000 description 7
- 230000003014 reinforcing effect Effects 0.000 description 6
- 239000003570 air Substances 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- 229920001577 copolymer Polymers 0.000 description 5
- 239000011230 binding agent Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 230000009977 dual effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229920000098 polyolefin Polymers 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 229920002292 Nylon 6 Polymers 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 239000012768 molten material Substances 0.000 description 3
- 229920002994 synthetic fiber Polymers 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 2
- 238000003490 calendering Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000002964 rayon Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000012209 synthetic fiber Substances 0.000 description 2
- 229920001634 Copolyester Polymers 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 150000001336 alkenes Chemical group 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000003776 cleavage reaction Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 239000006187 pill Substances 0.000 description 1
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Images
Classifications
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- 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
- D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
-
- 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
Definitions
- This invention relates to a thermal bonded, nonwoven fabric comprising base fibers and thermoplastic fusible fibers such as low melt polyester or conjugate fibers disposed on one or both surfaces thereof, which fusible fibers form thermobonds at temperatures substantially below the melting and softening temperature of the base fibers; and to a method of making said nonwoven fabric.
- Prior art attempts to solve the pilling and fraying problems associated with entangled fiber fabrics have primarily centered around the utilization of an extraneous binder to supplement the mechanical bonding resulting from the interfiber frictional engagement attributable to the entanglement process.
- binders suitable for this purpose introduce undesirable properties into the entangled fabric such as harshness and reduced hand and drape.
- such binders also make the resulting fabrics unsuitable for certain medical and surgical applications, such as for wound dressings.
- extraneous binder material will fill the interfiber spaces of a fabric, altering its capillarity and total absorbency.
- Fusible fibers have been used for overall reinforcement of an entangled fabric.
- U.S. Patent No. 3,485,706, in Example 66 describes the formation of a multilayered entangled fabric having a 54.256 g/m2 (1.6 oz.yd.2) center or reinforcing layer containing thermoplastic fibers and two 20.343 g/m2 (0.6 oz./yd.2)webs of staple length polyethylene terephthalate on either side thereof.
- the center or reinforcing layer comprises 88 percent continuous filament polyethylene terephthalate fibers and 12 percent of a continuous filament copolymer fiber made of 20 percent polyethylene isophthalate and 80 percent polyethylene terephthalate.
- the fabric After entangling, the fabric has an abrasion resistance (measure in minutes to hole formation) of 1.
- the fabric is then heated at 230°C for 2 minutes at 13.78 bar (200 psi) to fuse the copolymer fiber.
- the resultant fabric has an abrasion resistance of 15 minutes to hole formation.
- this does not relate directly to surface abrasion resistance, and does not indicate good surface tie-down of the fibers, or a lack of pilling and fraying.
- the fusible fiber is totally melted, loosing all fiber identity which alters the initial fibrous structure and results in a harsh feel.
- Patent 3,494,821 in Example XIV, discloses an entangled fabric formed from a 64.429 g/m2 (1.9 oz./yd.2) reinforcing layer of 88 percent continuous filament polyethylene terephthalate fibers and 12 percent continuous filament copolymer fibers of 80 percent polyethylene terephthalate and 20 percent polyethylene isophthalate, and a single 50.865 g/m2 (1.5 oz./yd.2)layer of staple length polyethylene terephthalate fibers. After entangling, the fabric is heated to 230°C for 20 seconds under 0.034 bar (0.5 psi) to fuse the copolymer fibers. No abrasion resistance is recited.
- the overall fabric structure and, hence, the performance characteristics are substantially affected by the use of a high percentage of continuous filament fibers in the reinforcing layer, and the initial formation using, but subsequent melting of a relatively high amount of fusible fibers.
- reinforcement and abrasion resistance in terms of minutes to hole formation are shown, there is no recitation of surface tie-down of the fibers and no apparent effort to achieve surface tie-down with a minimum of effect on the overall fabric structure and performance characteristics.
- Fusible fibers have also been used as a surface layer for a layer of carded fibers.
- the Tendersorb surgical dressing sponge manufactured by Kendall has heat fused polyester surface layers surrounding a center ply of carded rayon and polyester fibers. The dressing sponge suffers from undue linting of fibers.
- EP-A-127 851 which represents a state of the art under Article 54(3) EPC for the contracting states DE and NL, discloses an entangled non woven fabric having enhanced surface abrasion resistance comprising an entangled layer of base fibers having a layer of fusible fibers at a surface thereof, the fusible fibers being thermobonded to each other and to the base fibers at fiber intersections, wherein the base fibers are rayon fibers, polyester fibers or polypropylene fibers and the fusible fibers may be conjugate sheath/core polyethylene/polyester fibers.
- This fabric shows high strength, bulkiness and flexibility without fluff of the fibers on the surface or cleavage of the laminate plys.
- a fibrous web comprising a layer of base fibers and a surface layer of fusible fibers, passing columnar jets of fluid under pressure through said web to entangle the fibers of the web and heating the resultant web to soften or melt at least a part of the fusible fibers. Since, however, the overall fabric is entangled before the structure is heated, the fabric characteristics of the base layer are altered.
- thermoplastic fusible fibers there is provided on one or both surfaces of an entangled fiber web a thin layer of thermoplastic fusible fibers.
- the major fiber constituent of the fabric of the present invention hereinafter referred to as "base fibers” includes any fiber that is capable of being formed into an entangled fabric. Examples of such fibers are polyester, nylon, cotton, or other natural or synthetic fibers.
- the fusible fibers are thermobonded creating a thermobonded entangled network of fusible fibers and base fibers at the surface of the fabric. This surface network provides a fabric with enhanced surface tie-down of fibers achieved with a relatively low level of entangling in the overall fabric and at little increase in cost, and without substantially effecting the fabric characteristics of the base layer.
- Thermoplastic fusible fibers suitable for use in the present invention include polyolefin fibers having a melting temperature in the range of about 163-171°C.
- polyolefin fibers refers to manufactured fibers in which the fiber-forming substance is any long chain synthetic polymer comprised of at least 85 percent by weight of ethylene, propylene, or other olefin units, except amorphous (non-crystalline) polyolefins qualifying as rubber. It is, of course, within the scope of this invention to use other thermoplastic fusible fibers so long as they have a thermobonding temperature significantly less than the base fibers. An example of such other thermoplastic fusible fibers is a low melt polyester fiber.
- conjugate fibers provide a significant improvement in the fabric to accomplish the desired results
- a still further improvement is obtained by using conjugate fibers.
- conjugate fibers When using conjugate fibers, the integrity of the fibers can be maintained through many varieties of heat treatment, which has many obvious advantages.
- the conjugate fibers have an exposed low melting point component that is melted and fused to adjacent conjugate fibers and base fibers to provide enhanced surface abrasion and reduce the linting, pilling or fraying of the surface fibers.
- the base fibers are of staple length and in excess of 0.635 cm (1/4 inch) in length and normally from about 1.27 cm (1/2 inch) to about 5.08 cm (2 inches) or longer in length.
- Typical base fibers that can be used are polyester and Nylon 6, which have melting temperatures in the range of about 250-288°C and about 213-221°C, respectively, which melting temperatures are significantly greater than the polyolefin fibers referred to above.
- the denier of the fibers should be such as to allow bending of the fibers and should be on the order of about 0.11 to 0.67 tex (1 to 6 denier), with the preferred range being from about 0.17-0.39 tex (1-1/2 to 3-1/2 denier).
- the fusible fibers may be disposed on one or both surfaces of a layer of base fibers, which layer of fusible fibers can be added either prior or subsequent to the entangling of the base fibers.
- subsequent heating e.g., by hot calendering
- the fusible fibers are thermobonded to each other at their points of intersection or tangency.
- a web of base fibers such as polyester is formed with a thin layer of fusible fibers such as sheath/core polyethylene/polyester conjugate fibers on one or both surfaces thereof.
- the web of base and thermoplastic fibers is then entangled to provide interfiber frictional bonds.
- the fusible fibers are disposed on the side opposite to that exposed to the jets during the entanglement process.
- a layer of conjugate fibers is initially laid down on a conveyor on top of which is located a web of base fibers and an outer layer of conjugate fibers.
- This composite web is then passed through a mechanism one or more times where the entanglement of the fibers takes place by the introduction of high pressure columns of fluid, such as water jets, as disclosed in detail in Evans U.S. Patent 3,485,706.
- the resulting fabric consists of outer relatively thin layers of mixed conjugate and base fibers and a relatively thick intermediate layer of base fibers.
- a thin layer of mixed conjugate and base fibers will be disposed on a relatively thick layer of base fibers.
- the entangled fabric is then passed through a heating means, such as a hot air oven, where the low melting point component of the conjugate fibers are melted and bonding occurs at the point of intersection and tangency of the conjugate fibers and the base fibers.
- a heating means such as a hot air oven
- the conjugate or fusible fibers are introduced before the base fiber web is entangled.
- the fusible fibers are not entangled into the base layer, it is essential that the fusible fibers and base fibers be selected so as to effect specific adhesion of the fusible fibers to the base fibers following heat treatment.
- the essence of the invention in its broadest aspect, is the provision of thermobonded entangled network of fusible fibers and base fibers, on one or both surfaces of the fabric to achieve good surface abrasion and low linting or fraying of surface fibers without substantially effecting the fabric characteristics of the base layer in forming the final fabric.
- FIG. 1 there is shown an apparatus that can be used to provide a preferred embodiment of the fabric made in accordance with the invention in which the fabric is composed of a web 12 having a layer of base fibers 14 and an outer surface of fusible conjugate fibers 16.
- the web is supported on a liquid pervious support member such as an endless woven belt 18, which carries the web through an entangling mechanism 20 where a series of high pressure, fine, essentially columnar jets of water 22 impact the web, entangling the fibers.
- the high pressure water is supplied from manifold 24.
- the jets are arranged in rows disposed transversely across the path of travel of the belt 18.
- there is a vacuum means 26 pulling a vacuum, e.g, of up to 168.91-337.82 m bar [127-254 mm; (5 to 10 inches) of mercury, beneath the belt 18.
- Evans in U.S. Patent No. 3,485,706, describes a process and apparatus for rearranging/entangling fibrous webs by carrying such webs on a woven belt under a series of high pressure, fine, columnar jets of liquid. Apparatus of the general type disclosed by Evans can be used in the process of this invention, although typically the degree of entanglement contemplated by this invention is much less than that generally preferred by Evans.
- the entangled web 28 is then passed through an oven 30 where the fusible conjugate fibers are thermobonded to form a reinforced surface which prevents pilling and fraying thereof.
- a dual rotor mechanism 32 of the type disclosed in Ruffo et al US patent 3,768,118 is used to provide a web 12 in which the majority thereof consists of base fibers 14 disposed atop a layer of fusible conjugate fibers 16.
- the dual rotor mechanism is schematically illustrated, and as will be apparent from a review of the '118 patent, it can readily be adjusted to provide the desired web composition.
- the dual rotor apparatus is fed by cards 34,36 containing fusible conjugate and base fibers 16,14, respectively.
- the card 34 is used to provide the fusible conjugate fibers 16.
- the card 36 is used to provide the base fibers 14 such as suitable natural or synthetic fibers.
- conjugate fibers having fiber components with differing melting points.
- the higher melting point fiber component retains its integrity to contribute as a fiber to the finished non-woven fabric.
- An example of such conjugate fibers is polyester/ polyethylene conjugate fibers.
- sheath/core bicomponent fibers and even more preferred to employ sheath/core bicomponent fibers with polyethylene as the sheath and polyester as the core, although side-by-side conjugate fibers are also within the purview of the present invention.
- the fibers usually have a denier within the range of about (0.11 to about 0.67 tex) (1 to about 6), preferably and are in excess of about 0.635 cm (1/4 inch) in length up to about 7.62 or 10.16 cm (3 or 4 inches) long.
- the conjugate fibers employ high density polyethylene that has a density of at least about 0.94 and a melt index ("M.I.") by ASTMD-1238(E) (190°C, 2160 gms.) of greater than 1, preferably greater than about 10 and preferably about 20 to about 50.
- M.I. melt index
- the fibers will be composed of about 40 to 60 weight percent, and preferably 45 to 55 weight percent, polyester, the remainder being polyethylene.
- conjugate fibers having utility in the present invention are heterofil medium tenacity fibers.
- Such fibers which are available from ICI Fibers, Harrogate, North Yorkshire, England, under product codes 3.3/100/V303, 3.3/50/V303, 6.7/50/V302, 13/65/V302, and 13/100/V302 include sheath/core fibers wherein the sheath is a nylon 6 material and the core is a higher melting point nylon 66 material. Such fibers are particularly useful in combination with polyester base fibers.
- Other medium tenacity heterofil fibers available from ICI Fibers for use in the present invention will include polyester fibers sold under product codes 3.3/50/V544 and 3.3/90/V544.
- Other suitable sheath/core fibers include fibers having polyethylene or polyethylene terephthalate as a core material and an isophthalic copolymer as the sheath material.
- polymer pairs suitable for use in the conjugate fibers of the fabrics of the present invention are copolyester/polyester, nylon/polyester, and nylon 6/polypropylene.
- the conjugate fibers may comprise side-by-side, or sheath/core polymer configurations.
- the fusible conjugate fibers 16 concentrated on the undersurface of the fabric are mechanically entwined.
- the base fibers 14 will be primarily entangled with each other, but the fusible conjugate fibers on the outer surface will be entangled with the base fibers and with each other.
- the endless belt 18 transfers the entangled web onto conveying mechanisms including belts 38, 40 to the oven 30 where it is subjected to elevated temperatures to melt the low melting point component of the conjugate fibers, which has a lower melting temperature than the high melting point core of the conjugate fibers and the base fibers.
- the fusible fibers 16 fuse to the adjacent fibers to form bonds at points of fiber-to-fiber adjacency.
- the web is preferably thermal bonded under conditions of zero pressure, or very light pressure, so that the web is not significantly crushed or compacted during the thermal bonding step.
- the exact temperatures employed in the thermal bonding step will vary depending upon the weight and bulk density of the web, and upon the dwell time employed in the heated zone. For instance, bonding temperatures within the range from about 130°C to about 180°C have been found to be satisfactory for a web comprised of polyester base fibers and polyethylene/polyester bicomponent fibers of the type described above. Dwell times in the bonding zone will generally vary from about 2 seconds to one minute, and more normally will be from 3 to about 4 seconds.
- the important factor in selecting the heating conditions for optimum bonding when using conjugate fibers is to heat only the low melting point component to at least its melting point, but not to such a temperature that the high melting point component of the conjugate fibers or the base fibers could melt.
- the conjugate fibers retain their integrity, whereby the fibrous characteristics of the surface of the fabric is retained.
- the stiffness and loss of absorbency that can result from the total melting of fusible fibers, whereby the fibrous structure is destroyed and the remaining interfiber spaces or capillarity of the fabric is filled with the melted thermoplastic material, is avoided.
- the low melting point component of the conjugate fiber entraps some of the base fibers in a thermoplastic mass creating inclusion bonds.
- the molten material also tends to flow around the fibers, and to preferentially flow to fiber intersections.
- the molten material also coheres to like molten material on the bicomponent fibers to bond such fibers to one another to form adhesion bonds.
- the welds of the fused low melting point component e.g., polyethylene, solidify, and excellent fiber-to-fiber bonds are thereby formed. Simple exposure to ambient air will ordinarily provide adequate cooling.
- the thermal bonding step can be carried out by through-air bonding as illustrated in Figure 1 by the oven 30, or by other means, such as infrared heating, or other types of heating.
- Through-air bonding is accomplished by carrying the web on a porous conveyor belt through a zone where hot air is forced through the web. It can be carried through a heated zone between two porous screens or belts, or it can be carried on a rotating drum having a porous surface which is equipped to suck hot air through the web as it is passing around the drum. The exact method of effecting the heating has not been found to be narrowly critical.
- the thermal bonding step can be performed by passing the web between heated restraining belts, which apply moderate pressure, or between heated embossing or calendering rolls, which apply heavier pressure. With these latter methods, some compaction and densification of the web takes place. However, application of pressure increase the number of fiber contact points and thermal bonds.
- the fabric of the invention is collected as on a conventional windup roll 42.
- the surface of the fabric provided with fusible conjugate fibers is disposed on the side of the web opposite to the jets that provide for the entangling in the entangling mechanism 20.
- Such a fabric is disclosed and described in Figure 4 therein below.
- a card 46 is disposed downstream of the dual rotor mechanism to provide the web of fusible fibers 44 on the web 12.
- Such a fabric is disclosed and described in Figure 5, herein below.
- FIG. 2 Another way of producing a fabric having a thin outer surface of fusible fibers disposed on one side of a relatively thick layer of base fibers is shown in Figure 2.
- cards 50 and 52 of base fibers and fusible fibers, respectively are disposed on an endless conveyor 54 similar to the conveyor 18 referred to when discussing the apparatus shown in Figure 1.
- the seriatim cards 50,52 provide the composite web 56 which is directed through the entangling mechanism 20 and thereafter by way of conveyors 38 to calender rolls 58.
- the fusible fibers disposed on the outer surface of the entangled web 28 are heat fused to each other and preferably to the base fibers to strengthen the surface to prevent pilling or fraying.
- the bonded web is then wound up on a conventional windup roll 60.
- the surface formed with a layer of fusible fibers disposed on one or both sides thereof is entangled before it is introduced into the oven or the nip of the calender rolls.
- the essence of the invention is the provision of a thin layer of fusible fibers located on one or both outer surfaces of a thick layer of entangled base fibers, which fusible fibers are subsequently bonded to each other and to the base fibers to create a thermobonded entangled network of fusible fibers with the broadest aspect of the present invention, it is not essential that the fusible fibers be entangled with the base fibers, and it is within the scope of the invention to introduce the fusible fibers on one or both sides of one layer of base fiber after the web leaves the entangling mechanism, but before it is heated to fuse them to each other and the base fibers.
- One example of a fabric of the present invention is made up of 80 percent polyester and 20 percent conjugate fiber. However, depending on the surface strength desired, the fiber content ratio could be as low as 90 percent polyester, 10 percent conjugate fiber, and as high as 10 percent polyester and 90 percent conjugate fiber.
- the exact weight of the web is not critical, although useful weights have been found within the range of about 27.124 g/m2 (0.8 ounces/yd2) to about 67.81 g/m2 (2 ounces per square yard).
- Figure 3 illustrates a preferred embodiment of the fabric of the present invention, wherein sheath/core conjugate fibers 70 have been entangled with base fibers 72 at one surface of the fabric and thermobonded.
- the low melting point components or sheaths of the conjugate fibers has been heat fused to each other and to the base fibers of the web to form a thermobonded entangled network to the surface of the fabric.
- the low melting point component sheath melts and fuses to the sheath of adjacent conjugate fibers to form adhesion bonds 74.
- the low melting point component sheath flows around adjacent base fibers, is at 76, to form inclusion bonds.
- the remaining core of the conjugate fibers is seen at 78.
- Figures 4 and 5 illustrate cross-sections of fabrics made according to the present invention.
- a layer of fusible or conjugate fibers 80 have been provided at one surface of, and entangled with, a layer of base fibers 82 and thermobonded.
- the reinforced surface 84 so formed comprises a thermobonded entangled network of conjugate fibers and base fibers, strengthening the surface of the fabric which substantially effects the fibrous structure of fabric characteristics of the base layer.
- a layer of conjugate fibers 80 has been provided at both surfaces of a layer of base fibers 82 and entangled therewith.
- the fabric After heat treatment to thermobond the conjugate fibers to each other and to the base fibers, the fabric is provided with reinforced surfaces 84 and 86, each comprising thermobonded entangled network of conjugate fibers and base fibers.
- the layer of base fibers remain substantially uneffected by the method and means by which the reinforcing is accomplished.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Woven Fabrics (AREA)
- Treatment Of Fiber Materials (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
Claims (14)
- Procédé de fabrication d'une étoffe non tissée entremêlée présentant une résistance améliorée à l'abrasion en surface, comprenant une couche entremêlée de fibres de base comportant une couche de fibres thermocollantes à sa surface, les fibres thermocollantes étant thermocollées les unes aux autres ainsi qu'aux fibres de base au niveau des intersections des fibres, comprenant les étapes de :
fourniture d'un premier non tissé fibreux de fibres de base ;
passage de jets colonnaires de fluide sous pression au travers du non tissé afin d'entremêler les fibres du non tissé ;
superposition d'une couche mince fibreuse comprenant des fibres thermocollantes sur le premier non tissé entremêlé fibreux ; et
chauffage de la structure afin de thermocoller les fibres thermocollantes au niveau de leurs intersections afin de créer un réseau entremêlé thermocollé de fibres thermocollantes et de fibres de base au niveau de la surface de l'étoffe. - Procédé selon la revendication 1, dans lequel les fibres thermocollantes sont des fibres conjuguées qui comprennent un composant à point de fusion faible situé à l'extérieur et un composant à point de fusion élevé et les fibres conjuguées sont chauffées jusqu'à une température qui permet de thermocoller seulement ledit composant à point de fusion faible situé à l'extérieur d'où il résulte que les fibres conjuguées conservent leur intégrité pendant la fabrication de l'étoffe.
- Procédé selon la revendication 1 ou 2, dans lequel des couches de fibres thermocollantes sont disposées sur les deux surfaces du non tissé de fibres de base après que les fibres de base sont entremêlées.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AT85110212T ATE84083T1 (de) | 1984-08-16 | 1985-08-14 | Nichtgewobene verflochtene stoffbahn mit oberflaechig enthaltenden thermoplastischen fasern und verfahren zur herstellung derselben. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US64115884A | 1984-08-16 | 1984-08-16 | |
US641158 | 1984-08-16 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0171807A2 EP0171807A2 (fr) | 1986-02-19 |
EP0171807A3 EP0171807A3 (en) | 1989-06-07 |
EP0171807B1 true EP0171807B1 (fr) | 1992-12-30 |
Family
ID=24571184
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP85110212A Expired - Lifetime EP0171807B1 (fr) | 1984-08-16 | 1985-08-14 | Etoffe non-tissée entremêlée contenant des fibres thermoplastiques en surface et son procédé de fabrication |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP0171807B1 (fr) |
AT (1) | ATE84083T1 (fr) |
AU (1) | AU576618B2 (fr) |
BR (1) | BR8503891A (fr) |
DE (1) | DE3586931T2 (fr) |
NZ (1) | NZ212999A (fr) |
ZA (1) | ZA856209B (fr) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5336552A (en) | 1992-08-26 | 1994-08-09 | Kimberly-Clark Corporation | Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer |
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 |
US5643662A (en) | 1992-11-12 | 1997-07-01 | Kimberly-Clark Corporation | Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith |
US6500538B1 (en) | 1992-12-28 | 2002-12-31 | Kimberly-Clark Worldwide, Inc. | Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith |
US6534174B1 (en) | 2000-08-21 | 2003-03-18 | The Procter & Gamble Company | Surface bonded entangled fibrous web and method of making and using |
US6673158B1 (en) | 2000-08-21 | 2004-01-06 | The Procter & Gamble Company | Entangled fibrous web of eccentric bicomponent fibers and method of using |
Families Citing this family (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR880006719A (ko) * | 1986-11-12 | 1988-07-23 | 노기 사다오 | 전도성 시트의 제조방법 |
JPH0712371B2 (ja) * | 1986-12-10 | 1995-02-15 | 花王株式会社 | 吸収性物品 |
US5108827A (en) * | 1989-04-28 | 1992-04-28 | Fiberweb North America, Inc. | Strong nonwoven fabrics from engineered multiconstituent fibers |
ATE141965T1 (de) * | 1990-12-14 | 1996-09-15 | Hercules Inc | Vliesstoff mit hoher festigkeit und geschmeidigkeit |
US5254399A (en) * | 1990-12-19 | 1993-10-19 | Mitsubishi Paper Mills Limited | Nonwoven fabric |
WO1993023596A1 (fr) * | 1992-05-08 | 1993-11-25 | Gates Formed-Fibre Products, Inc. | Materiau composite moulable non tisse ameliore et procede de fabrication |
US5786060A (en) * | 1995-09-28 | 1998-07-28 | Japan Vilene Company, Ltd. | Female member for face fastener and method of producing the same |
GB9623924D0 (en) * | 1996-11-18 | 1997-01-08 | Bonded Fibre Fab | A high durability nonwoven fabric |
US5773120A (en) * | 1997-02-28 | 1998-06-30 | Kimberly-Clark Worldwide, Inc. | Loop material for hook-and-loop fastening system |
EP0896080B1 (fr) * | 1997-08-06 | 2003-09-10 | Fleissner GmbH & Co. Maschinenfabrik | Méthode de fabrication d'un non-tissé composite volumineux, dispositif de réalisation et produit |
JP4008136B2 (ja) * | 1998-02-23 | 2007-11-14 | 日本バイリーン株式会社 | 面ファスナー雌材及びその製造方法 |
US7112712B1 (en) | 1999-11-10 | 2006-09-26 | Protex Healthcare (Uk) Limited | Dressing |
DE10105784A1 (de) * | 2001-02-07 | 2002-08-08 | Fleissner Gerold | Wasservernadeltes Kompositvlies aus Stapel- und Endlosfasern und Verfahren zur Herstellung |
DE10314552A1 (de) * | 2003-03-31 | 2004-10-14 | Rieter Automatik Gmbh | Verfahren und Vorrichtung zur Herstellung eines Verbundvlieses |
WO2005094245A2 (fr) * | 2004-03-01 | 2005-10-13 | Filtrona Richmond, Inc. | Meche de fibre a deux composants |
JP6024915B2 (ja) * | 2013-03-28 | 2016-11-16 | Jnc株式会社 | 不織布およびそれを用いて得られた製品 |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3493462A (en) * | 1962-07-06 | 1970-02-03 | Du Pont | Nonpatterned,nonwoven fabric |
US4081582A (en) * | 1976-10-20 | 1978-03-28 | Johnson & Johnson | Fibrous material and method of making the same |
JPS59223350A (ja) * | 1983-05-26 | 1984-12-15 | 株式会社クラレ | 不織布およびその製法 |
-
1985
- 1985-08-05 NZ NZ212999A patent/NZ212999A/en unknown
- 1985-08-14 AT AT85110212T patent/ATE84083T1/de not_active IP Right Cessation
- 1985-08-14 DE DE8585110212T patent/DE3586931T2/de not_active Revoked
- 1985-08-14 EP EP85110212A patent/EP0171807B1/fr not_active Expired - Lifetime
- 1985-08-15 ZA ZA856209A patent/ZA856209B/xx unknown
- 1985-08-15 AU AU46243/85A patent/AU576618B2/en not_active Ceased
- 1985-08-15 BR BR8503891A patent/BR8503891A/pt unknown
Cited By (9)
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 |
US5418045A (en) | 1992-08-21 | 1995-05-23 | Kimberly-Clark Corporation | Nonwoven multicomponent polymeric fabric |
US5336552A (en) | 1992-08-26 | 1994-08-09 | Kimberly-Clark Corporation | Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer |
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 |
US5425987A (en) | 1992-08-26 | 1995-06-20 | Kimberly-Clark Corporation | Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material |
US5643662A (en) | 1992-11-12 | 1997-07-01 | Kimberly-Clark Corporation | Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith |
US6500538B1 (en) | 1992-12-28 | 2002-12-31 | Kimberly-Clark Worldwide, Inc. | Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith |
US6534174B1 (en) | 2000-08-21 | 2003-03-18 | The Procter & Gamble Company | Surface bonded entangled fibrous web and method of making and using |
US6673158B1 (en) | 2000-08-21 | 2004-01-06 | The Procter & Gamble Company | Entangled fibrous web of eccentric bicomponent fibers and method of using |
Also Published As
Publication number | Publication date |
---|---|
BR8503891A (pt) | 1986-05-27 |
NZ212999A (en) | 1987-05-29 |
EP0171807A3 (en) | 1989-06-07 |
DE3586931D1 (de) | 1993-02-11 |
AU576618B2 (en) | 1988-09-01 |
EP0171807A2 (fr) | 1986-02-19 |
ZA856209B (en) | 1987-03-25 |
AU4624385A (en) | 1986-02-20 |
DE3586931T2 (de) | 1993-04-29 |
ATE84083T1 (de) | 1993-01-15 |
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