EP0482749A1 - Genadelter Vliesstoff - Google Patents

Genadelter Vliesstoff Download PDF

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Publication number
EP0482749A1
EP0482749A1 EP19910308069 EP91308069A EP0482749A1 EP 0482749 A1 EP0482749 A1 EP 0482749A1 EP 19910308069 EP19910308069 EP 19910308069 EP 91308069 A EP91308069 A EP 91308069A EP 0482749 A1 EP0482749 A1 EP 0482749A1
Authority
EP
European Patent Office
Prior art keywords
batt
fibers
loops
fabric
low melt
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.)
Withdrawn
Application number
EP19910308069
Other languages
English (en)
French (fr)
Inventor
Paul William Eschenbach
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Milliken Research Corp
Original Assignee
Milliken Research Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Milliken Research Corp filed Critical Milliken Research Corp
Publication of EP0482749A1 publication Critical patent/EP0482749A1/de
Withdrawn legal-status Critical Current

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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
    • 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
    • D04H1/46—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 by needling or like operations to cause entanglement 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
    • D04H11/00—Non-woven pile fabrics
    • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
    • 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
    • D04H18/00—Needling machines
    • D04H18/02—Needling machines with needles

Definitions

  • This invention relates to a nonwoven fabric and a method of making same and, more particularly, to a nonwoven fabric made from a needled batt of non-woven staple fibers from a blend of fibers including low melt fusible fibers.
  • U. S. Patent No. 3,674,618 issued July 4, 1972 to Spann discloses a process for making an imitation sliver knit pile fabric wherein a thin thermoplastic film is placed on a non-woven layer of stable fibers. The fibers are needled through the film and the film is thermally bonded to the fibers. The layer of fibers is then napped, sheared and polished to produce an apparel fabric that is soft and pliable.
  • U. S. Patent No. 3,347,735 issued October 17, 1967 to Sissons shows attaching a reinforcing member to a surface of a web of stable fibers.
  • the web and reinforcing member are needle punched from the side of the web opposite the reinforcing member to force fibers through the reinforcing member to form fiber tufts.
  • the resulting product is immersed in boiling water to crimp the fibers.
  • U. S. Patent 4,391,866 issued July 5, 1983 to Pickens, et al. describes a cut pile fabric made from a needled batt of non-woven fibers in which a series of loops is aligned in the cross-machine direction and then tigered to break a number of the filaments in the formed loops. Then to even out the surface of the fabric the surface of the fabric is polished and sheared in order to produce a suitable smooth pile surface.
  • Figures 1 & 7 schematically represent the preferred embodiments of producing the cut pile fabric.
  • Figures 1 & 7 show a continuous process but obviously the fabric or webs being processed can be taken up at the end of any step in the process and carried on a roll or like to the next step in the process so long as the sequential steps of the process shown are followed.
  • FIGs 1 - 6 illustrate one preferred form of fabric 10 and the method of manufacturing same.
  • Non-woven staple fibers 12 are laid up in a continuous web 11, as in Figure 1, using, for instance, a conventional lapper 13 whereupon as the web 11 is advanced past a needle loom 15, it is needled into a continuous batt 14, using conventional needles.
  • the batt 14 may be needled from both sides or from one side, as shown depending upon the materials of the fibers and the desired weight of the finished fabric.
  • the needled batt 14 may be turned over or reversed before it is fed to a loop-forming needle loom 17.
  • the turning of the batt 14 may be accomplished by rolling the batt onto a roller (not shown) as it leaves the needle loom 15, after which the roller is reversed and the batt 14 is fed to the needle loom 17 so that the batt 14 is punched from the side of the batt opposite to the single needle. If the batt 14 was needled from both sides, it is fed to the needle loom 17 oriented so that the needles penetrate first into the first punched side so that the loops project from the last-punched side. The batt 14 is advanced past the needle loom 17 where it is formed into loops 18.
  • the needle loom 17 uses fork needles 19 which pass through one surface, such as a back surface 20, of the batt 14 to push fibers caught on the ends of the needles through another surface, such as a face surface 22, to form the loops 18 extending from said face surface.
  • the forked needles are aligned in the transverse direction and staggered in the machine direction so that the openings in the loops in the machine direction are staggered from row to row in the machine.
  • a brush conveyor 26 is used to allow the staggered needles to pass therethrough randomly after needling and to mount the needles 19 so that the openings in the form run perpendicular to the machine direction of the needle loom 17.
  • the batt 14 is moved downstream to where a backing 24, such as a coating of latex, Figure 1, or the like, is applied to the back surface 20 using a conventional latex applicator 25 to lock the fibers 12 of the batt 14 and, if particular, the fiber ends of the loop 18 that are still in the batt and to add stiffness to the batt.
  • a backing 24, such as a coating of latex, Figure 1, or the like is applied to the back surface 20 using a conventional latex applicator 25 to lock the fibers 12 of the batt 14 and, if particular, the fiber ends of the loop 18 that are still in the batt and to add stiffness to the batt.
  • the applicator 25, as shown in Figure 1, is a commercially available type which applies the backing 24 as the batt 14 is moved past the applicator with the backing surface facing upward.
  • the back surface 20 may have the backing 24 formed by fusing (not shown) using an appropriate heat roll or oven 28 as shown in Figure 7, or the like, which is intended to lock the ends of the fibers forming the loops and to add stiffness to the batt.
  • the backing 21 gives strength and stability, as well as stiffness, to the finished fabric.
  • the backed looped batt 14 ( Figure 6) with the staggered loops 18 facing downward is passed over a guide roll 30 to the loop cutting rotor 32 of the type disclosed in U. S. Patent No. 3,977,055.
  • the loop cutting rotor 32 Located on both sides of the rotor 32 are a pair of adjustable rolls 34 and 36 mounted, respectively, in support tracks 38 and 40. Support tracks allow the rolls 34 and 36 to move upward and downward to adjust the position of the looped batt 14 with respect to the blades 42 in the cutting rotor 32.
  • the blades 42 sever almost 100% of all of the loops 18 with a minimum of waste to provide a cut pile fabric 46.
  • the rotor 32 can be driven in the direction of travel of the looped batt 14 ( Figure 4) by the motor 44 or opposite to the direction of travel of the batt ( Figure 5). After the loops 18 of the batt 14 have been cut the cut pile fabric 46 is delivered to the take-up 48 by the driven roll 50 whereat it is taken up.
  • a typical fabric made by the herein-disclosed apparatus and method will be comprised of 18 denier, 34" staple nylon having a pile height of 4-5 mm. Depending on the use of the cut pile fabric the weight can vary from 6 to 30 oz/yd 2 . If the apparatus of Figure 7 is employed the web 12 can be blended with 3 - 6 denier low melt polyethylene or like fibers.
  • a plurality of layers of non-woven staple fibers of 34" lengths of nylon was lapped into a continuous web 11 which was then needle punched to form a continuous batt 14.
  • the needle punched batt 14 was then punched on a loom 17 to form loops 18.
  • the fork needles 19 used on the needle loom 17 were oriented with the opening between the points of the fork disposed perpendicular to the machine direction.
  • the batt 14 was then moved past applicator 25 whereupon a backing 24 of latex, identified as SBR, was applied on the back surface 20 at the rate of 8 ounces per square yard and was dried.
  • the latexed batt 14 was then passed at the rate of 15 feet per minute through the rotor 32 rotating at suitable r.p.m. in a counterclockwise or clockwise direction to cut the loops 18.
  • the fabric 10 may be dyed in conventional fashion or the fibers 12 may have been stock dyed or solution dyed the desired color so that the finished fabric would reflect that color.
  • Figure 7 shows a modification of the invention in which the batt includes a pre-determined amount of low melt fusible fibers which will fuse the batt 14 in the oven 28.
  • the particular low melt fusible fiber and the amount blended is not specifically critical except that in the preferred form of the invention the batt 14 is a blend of 80%, 18 denier 34 solution dyed polypropylene fibers and 20%, 6 denier 1-7/8" clear polyethylene.
  • the amount of low melt fusible fiber can vary from 10 - 35% and the amount of remaining fibers shall vary accordingly. In the preferred case above the oven is operated at approximately 275 ° F for a period of five minutes to heat set the batt 14.
  • the product is basically nylon.
  • the major component of the blended batt 14 is 85 - 70% of 18 denier, 3" staple solution-dyed nylon while the low melt fiber is a combination of nylon 6 and nylon 12 which is 15 - 30% of the total batt 14.
  • the low melt nylon combination fibers are 4.5 denier with a staple length of 51 millimeters.
  • the herein-described batt 14 is placed in the oven operating at a temperature of 300 ° F and allowed to dwell for about five minutes before being cooled to complete the fusion of the fibers.
  • the above combination of fibers provides improvement in bearding, higher tensile strength and a high degree of dimensional recovery.
  • This batt is very stable due to the low moisture absorption of the nylon 6 and nylon 12 combination for the low melt staple fiber.
  • the fabric can be needled to form loops with the loops remaining intact or cut as shown in Figures 1 - 7.
  • the fabric can also be needled only for use as a carpet backing material, etc.
  • the treatment after fusion depends on the ultimate use of the fabric but usually includes a flexing step to make the fusion bonded batt more pliable and/or flexible. This step may include running through a compactor or over an edge to break up the bond of the fibers during or after cooling of the low melt fibers. Another possibility is to employ a set of rotating wheels to work the surface of the batt. All of these treatments are directed to provide pliability to otherwise a stiff, boardy fabric.
  • Fabrics made by the fusion bonding step of bonding the low melt fibers to the other fibers in the batt provides a fabric which is non-boardy with excellent appearance and can be readily sewn if the use of same requires such.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
EP19910308069 1990-10-26 1991-09-03 Genadelter Vliesstoff Withdrawn EP0482749A1 (de)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US60342490A 1990-10-26 1990-10-26
US603424 1990-10-26
US61897790A 1990-11-28 1990-11-28
US618977 1990-11-28
US71901991A 1991-06-21 1991-06-21
US719019 1991-06-21

Publications (1)

Publication Number Publication Date
EP0482749A1 true EP0482749A1 (de) 1992-04-29

Family

ID=27416879

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19910308069 Withdrawn EP0482749A1 (de) 1990-10-26 1991-09-03 Genadelter Vliesstoff

Country Status (3)

Country Link
EP (1) EP0482749A1 (de)
JP (1) JPH04257358A (de)
CA (1) CA2051060A1 (de)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1009137C2 (nl) * 1997-05-12 2000-09-20 Nygaard Witvoet & Partners Tapijt en werkwijze en installatie voor het vervaardigen daarvan.
US6342285B1 (en) 1997-09-03 2002-01-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US6783834B2 (en) 1997-09-03 2004-08-31 Velcro Industries B.V. Loop material for touch fastening
US7785095B2 (en) 2001-03-14 2010-08-31 Velcro Industries B.V. Molding apparatus and related methods
EP2540891A1 (de) * 2011-06-28 2013-01-02 Oleg Muzyrya Verfahren zur Herstelleung eines Materials zur Schall-und Wärmedämmung
US8673097B2 (en) 2007-06-07 2014-03-18 Velcro Industries B.V. Anchoring loops of fibers needled into a carrier sheet
US8678807B2 (en) 2000-10-24 2014-03-25 Velcro Industries B.V. Molding apparatus and related methods
US8753459B2 (en) 2002-12-03 2014-06-17 Velcro Industries B.V. Needling loops into carrier sheets
US9078793B2 (en) 2011-08-25 2015-07-14 Velcro Industries B.V. Hook-engageable loop fasteners and related systems and methods
US9119443B2 (en) 2011-08-25 2015-09-01 Velcro Industries B.V. Loop-engageable fasteners and related systems and methods

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3341386A (en) * 1966-01-11 1967-09-12 Collins & Aikman Corp Method of making frieze effect fabrics
US4391866A (en) * 1980-06-16 1983-07-05 Ozite Corporation Cut pile fabric with texturized loops

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3341386A (en) * 1966-01-11 1967-09-12 Collins & Aikman Corp Method of making frieze effect fabrics
US4391866A (en) * 1980-06-16 1983-07-05 Ozite Corporation Cut pile fabric with texturized loops

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1009137C2 (nl) * 1997-05-12 2000-09-20 Nygaard Witvoet & Partners Tapijt en werkwijze en installatie voor het vervaardigen daarvan.
US6342285B1 (en) 1997-09-03 2002-01-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US6598276B2 (en) 1997-09-03 2003-07-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US6783834B2 (en) 1997-09-03 2004-08-31 Velcro Industries B.V. Loop material for touch fastening
US8678807B2 (en) 2000-10-24 2014-03-25 Velcro Industries B.V. Molding apparatus and related methods
US7785095B2 (en) 2001-03-14 2010-08-31 Velcro Industries B.V. Molding apparatus and related methods
US8753459B2 (en) 2002-12-03 2014-06-17 Velcro Industries B.V. Needling loops into carrier sheets
US8673097B2 (en) 2007-06-07 2014-03-18 Velcro Industries B.V. Anchoring loops of fibers needled into a carrier sheet
FR2977261A1 (fr) * 2011-06-28 2013-01-04 Oleg Muzyrya Procede de fabrication d'un materiau d'isolation acoustique et thermique
EP2540891A1 (de) * 2011-06-28 2013-01-02 Oleg Muzyrya Verfahren zur Herstelleung eines Materials zur Schall-und Wärmedämmung
US9078793B2 (en) 2011-08-25 2015-07-14 Velcro Industries B.V. Hook-engageable loop fasteners and related systems and methods
US9119443B2 (en) 2011-08-25 2015-09-01 Velcro Industries B.V. Loop-engageable fasteners and related systems and methods
US9872542B2 (en) 2011-08-25 2018-01-23 Velcro BVBA Loop-engageable fasteners and related systems and methods

Also Published As

Publication number Publication date
CA2051060A1 (en) 1992-04-27
JPH04257358A (ja) 1992-09-11

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