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
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
  • D04H1/08—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres and hardened by felting; Felts or felted products
  • D04H1/10—Felts made from mixtures of fibres
• • 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 blends of cotton and polyester copolymer binder fibers and to batts made from such blends.
• the batts are made by means of a thermal bonding process; and they are durable enough to withstand the stresses of repeated washings.
• the blends are of a high bulk and a low density.
• European Patent publication 227,914 seems to teach consolidation of cotton swabbing by superficially fusing thermoplastic fibers uniformly distributed throughout the cotton.
• the temperature for the fusing appears to be about 250°F.
• the remainder or core of the fiber may be of higher melting point, and thus would remain in fiber form as a bridging structure after the lower melting material has fused and performed its binding function.
• Such bicomponent binder fibers have been disclosed, for example, in U.S. Patents No. 3,589,956 and 4,068,036. It will be understood that, for best results when using bicomponent fibers, some corresponding adjustment of proportions may be advisable to optimize results in relation to those preferred when monocomponent binder fibers are blended with cotton.
• the batts of this invention are useful for fiberfill, insulation, padding, resilient cushioning, and the like.
• the batts are generally made to have a density of 0.018 to 0.038 grams per cubic centimeter. These batts exhibit excellent washability and have high strength as indicated by large values of adjusted total work-to-break. Washability is a measure of the durability of batts of this invention through automatic washing and drying cycles. It has been found that batts with too little binder fiber disintegrate during laundering because of inadequate fiber-to-fiber adhesion and that batts with too much binder fiber are boardy and are broken apart during laundering because of being too stiff and brittle. Batts of this invention exhibit an appearance after laundering which is superior to batts made using the same kinds of materials under the same conditions but with less than 15 or more than 25 weight percent copolyester binder fibers. Test methods used to determine these qualities are set out below.
• Denier - The denier of a filament is calculated from its fundamental resonant frequency, determined by vibrating a 2 to 4 cm length of filament under tension with changing frequency. (ASTM D1577-66), part 25, 1968).
• Stick Temperature - Fiber stick temperature is measured as described by Beaman and Cramer, J. Polymer Science 21, page 228 (1956).
• a flat brass block is heated electrically to raise the block temperature at a slow rate.
• the fiber sample is suspended under slight tension between glass rods over and near the surface of the block. At intervals, the fiber is pressed against the block for 5 seconds with a 200 gram brass weight which has been in continuous contact with the heated block.
• the fiber stick temperature is the temperature of the block when the fiber sticks to it for at least 2 seconds after removing the weight.
• the strength of the batts of this invention is measured by determining the Adjusted Total Work to Break.
• the Adjusted Total Work to Break is determined in accordance with ASTM D885 - 85 as follows:
• Samples of the batt to be tested are cut 1 inch wide and 7 inches long. Ten of those samples are cut with the length in the machine direction and ten are cut with the length in the transverse direction. The samples are conditioned for 2 hours at about 75°F and 55% relative humidity.
• Each of the samples is mounted in the jaws of a tensile testing machine with a 5 inch gage length; and the samples are pulled with the results recorded on a stress-strain curve generated by the testing machine.
• Work-to-Break is the average value of ten samples. Work-to-Break is determined for the machine direction and for the transverse direction. Total Work-to-Break is the sum of the machine direction Work-to-Break and the transverse direction Work-to-Break.
• the samples are judged by their appearance on a scale of 1 to 4, with 1 being worst -- having fibers lumping together and exhibiting nonuniformity -- and 4 being best -- having excellent appearance with uniformity similar to the unwashed original sample.
• a batt appearance of 2.5 is considered acceptable for purposes of this invention.
• Example 1 Preparation of the Blends -
• blends of fibers were made in accordance with the present invention.
• Copolyester binder fibers were used which had ethylene and a 70/30 mole ratio of terephthalate and isophthalate groups, a stick point of 194°F, and a melting point of 288°F.
• the binder fibers had a denier of about 3 and an average length of about 1.5 inches.
• Example 2 Preparation of the Batts - In this example, blends from Example 1 were thermally bonded to yield batts of the present invention.
• Blends from Example 1 were carded on a 40 inch roller top carding machine to yield a continuous web which was crosslapped to a continuous batt having a basis weight of 3 to 8 ounces per square yard.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Nonwoven Fabrics (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Applications Claiming Priority (2)

Publications (2)

Family

ID=23421968

Family Applications (1)

Country Status (8)

Cited By (3)

Families Citing this family (2)

Citations (3)

Family Cites Families (4)

• 1990
  • 1990-05-30 CA CA002017836A patent/CA2017836A1/fr not_active Abandoned
  • 1990-06-04 KR KR1019900008189A patent/KR910001129A/ko not_active Application Discontinuation
  • 1990-06-04 BR BR909002640A patent/BR9002640A/pt unknown
  • 1990-06-05 JP JP2145556A patent/JPH0369649A/ja active Pending
  • 1990-06-05 CN CN90104558A patent/CN1083026C/zh not_active Expired - Fee Related
  • 1990-06-05 EP EP19900110599 patent/EP0401738A3/fr not_active Ceased
  • 1990-06-05 AR AR90317025A patent/AR243246A1/es active
  • 1990-06-05 AU AU56271/90A patent/AU639866B2/en not_active Ceased

Patent Citations (3)

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