Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
• • 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
  • D04H13/00—Other non-woven fabrics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • 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
  • D04H1/492—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 by fluid jet
• • 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
  • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/593—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
  • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
  • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
  • D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic Table
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M17/00—Producing multi-layer textile fabrics
  • D06M17/04—Producing multi-layer textile fabrics by applying synthetic resins as adhesives
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
  • D06M23/08—Processes in which the treating agent is applied in powder or granular form
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
  • D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/58—Material containing hydroxyl groups
  • D06P3/60—Natural or regenerated cellulose
  • D06P3/62—Natural or regenerated cellulose using direct dyes
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/58—Material containing hydroxyl groups
  • D06P3/60—Natural or regenerated cellulose
  • D06P3/66—Natural or regenerated cellulose using reactive dyes
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
  • D06M2101/02—Natural fibres, other than mineral fibres
  • D06M2101/04—Vegetal fibres
  • D06M2101/06—Vegetal fibres cellulosic
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
  • D06M2200/50—Modified hand or grip properties; Softening compositions
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/659—Including an additional nonwoven fabric
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/659—Including an additional nonwoven fabric
  • Y10T442/666—Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/689—Hydroentangled nonwoven fabric

Definitions

• This invention relates to spunlaced fabrics and particularly to spunlaced fabrics suitable for durable uses and reuses.
• the invention more particularly relates to chamois-type materials.
• Spunlaced fabrics are made by hydroentangling webs of fibers with high energy water jets as basically described in Evans et al. US Patent No. 3,485,706.
• the webs may be made of a variety of fibers such as polyester, cellulose (rayon, cotton and wood pulp), acrylic, and other fibers as well as some blends of fibers.
• the fabrics may be further modified to include antistatic and antimicrobial properties, etc. by incorporation of appropriate additive materials into the fiber or fiber webs.
• spunlaced fabrics and nonwovens in general is durability through multiple launderings. Thus, spunlaced fabrics have not been acceptable for most uses in apparel and garments except for single use garments such as medical gowns and limited use protective apparel.
• the filament or staple yarns are "knit" in a dense pattern into the fabrics and are quite resistant to the cyclic tensioning or working of the fabric.
• the laundered stitchbond fabric does not suffer as much of the damages seen with the ordinary un-reinforced spunlaced fabrics.
• the stitched structure has proven to be reasonably satisfactory in performance for durable and reusable mattress covers and withstands many hundreds of launderings. However, there are aesthetic and cost considerations of the stitched appearance that could make such a solution unattractive.
• binders tend to be very hard after they are cured and any place that it extends through to the surface will be noticeable to the touch. It would likely be quite irritating for example to a human wearing clothing made from such material.
• the second problem is that the binders often do not respond to dyes and printing like the fibers in the fabric. As such, the binder becomes noticeable and unsightly.
• chamois is a material used for its absorbency and softness. Natural chamois is made from treated animal skins. There are also many artificial chamois-type materials, but none providing very high durability with excellent absorbency. Summary of the Invention It has now been found that a durable fabric may be formed by bonding two layers of fabric together to form a composite fabric structure having the feel and appearance of a conventional spunlaced fabric sheet, but with significantly improved durability.
• the composite fabric structure comprises two layers of fabric bonded together such that the bonding is done with discrete bonding points between the layers and relatively closely spaced to one another. In particular, the bonds encompass portions of fibers from both layers of fabric without substantially penetrating through to the outer surface of at least one of the layers of fabric.
• Yet a further aspect of this invention is to provide an inexpensive yet durable and effective alternate to natural chamois and other artificial chamois materials.
• Figure 1 shows a highly schematic arrangement of the manufacturing process for making the fabric of the present invention
• Figure 2 is an enlarged fragmentary perspective view of the calender rolls for forming the composite fabric of the present invention
• Figure 3 is an enlarged fragmentary top view of the scrim used to create the bonds in the composite fabric
• Figure 4 is a fragmentary perspective view similar to Figure 2 showing a second arrangement for forming the composite fabric structure of the present invention
• Figure 5 is a cross sectional view of the composite fabric of the present invention showing a single bonding point.
• Figure 6 is a set of photographs showing the composite fabric material at high magnifications before further processing.
• Figure 7 is a set of photographs showing the composite fabric material at high magnifications after further processing.
• Figure 1 is a highly schematic drawing intended to convey the general understanding of the equipment and process while not overloading the drawing with detail.
• the preferred process essentially comprises three generally separate steps which are shown in sequence in Figure 1.
• the first step is the creation of two separate hydroentangled sheets by first and second fabric forming lines generally indicated by the reference numbers 20 and 30 at the upper and lower portions of the drawing.
• the process of forming hydroentangled sheets is generally described in Zafiroglu et al., US Patent No. 3,797,074 and Evans et al., US Patent No. 3,485,706 and which are incorporated herein by reference.
• Focusing on the second fabric forming line 30, the process comprises feeding a batt of fiber 32 to an airlay 35.
• the airlay 35 includes a toothed disperser roll 36 that rotates at high speed relative to the feed rate of the batt 32.
• the fiber is pulled out of the batt 32 by the disperser roll 36 and fed into an air flow in the nozzle 37.
• the fiber is collected on a consolidation screen belt 41.
• the fiber on the belt 41 now generally referred to as a web, is carried onto a second belt 42 suited for supporting the web under a series of high energy water jets generally indicated by the number 45.
• the high energy water jets entangle the fibers forming a fabric.
• the fabrics are subjected to hydroentangling from the underside by conveyance around a roll 49 so as to be impinged by a second series of high energy water jets 50.
• the fabric is thereafter dried by suitable equipment such as the steam heated rolls 54 and 55 to produced a base fabric 59.
• Both the first and second fabric lines 20 and 30 are essentially similar, producing base fabrics 29 and 59, respectively. It is preferred that the base fabrics are collected on a roll at the end of each line 20 and 30 so that production rates of each line 20, 30 and the composite assembly line 60 (described below) may be optimized and the lines can be operated independently for maximum up time.
• a composite assembly line in the middle of Figure 1 is generally indicated by the number 60.
• the base fabric 59 is provided into the composite assembly line 60 and a mesh bonding layer 61 of a thermoplastic netting is provided thereon from a supply roll 62.
• the mesh bonding layer 61 is illustrated in Figure 3 and comprises a very fine netting like material with dots 63 at the interconnections of thermoplastic material.
• the fine strands 64 of thermoplastic material hold the mesh bonding layer together and effectively dictates the spacing of the bonding points of the composite fabric 99 or netting together.
• the dots 63 are smaller than a millimeter in diameter and about one (1) millimeter from adjacent dots 63.
• the fine strands 64 are quite small, being a few microns in thickness. Such materials are utilized commercially in medical and automotive products and are available from Smith and Nephew, Ltd. and Applied Extrusion Technologies, as well as other sources.
• the second base fabric 29 is laid over top of the mesh bonding layer 61 forming a sandwich with fabrics 29 and 59 on the top and bottom thereof.
• the sandwich is then subjected to calendering between calender rolls 71 and 72 under controlled temperature, pressure and speed to melt the thermoplastic material in the mesh bonding layer 61.
• the dots 63 of the mesh bonding layer 61 form discrete globules 65 (see Figure 5) of binder such that the fine connecting strands 64 between the dots 63 are severed and the material therein largely retracts into the globules 65.
• a dotted line 75 is provided to show the interface between the two layers of base fabric 29 and 59.
• Each of the base fabrics are made up of a great number of individual fibers 77.
• the fibers are randomly arranged in the fabrics 29 and 59, however, it is generally known that the fibers preferentially lay flat in the web prior to hydroentangling.
• the fibers are described as having an X-Y orientation.
• some of the fibers are pushed through the fabric to have a Z component extending up and down in the fabric.
• the Z component fibers are tangled into and with the X-Y fibers which continue to comprise a majority of the fibers, forming the stable and strong hydroentangled fabric.
• some fibers 78 have a portion which extend in the Z direction though the fiber is longer than the Z direction thickness of the fabric. Thus, the fibers are not necessarily entirely vertically or Z oriented. It should also be seen that some of the Z fibers 78 are also enmeshed or encompassed into the globule 65 of binder.
• the globule 65 is within the fabric and does not extend to the surface.
• the composite fabric surface retains the softness and appearance characteristics of the base fabric constituted by fibers 77.
• the globule 65 preferably encase or surround on at least half of the surface of fibers 77 that are at least one fiber thickness from the boundary between the two base fabrics.
• fibers 77 several fiber thicknesses from the boundary are encased in the globules 65 of binder. This deep fiber bonding is a result of the substantial pressure employed by the calender rolls.
• the extent of involvement of the fibers in the globules may also be described as the percentage of the thickness of each base fabric which is involved with the globules 65.
• the globules not extend through 100% of the base fabric because this would mean that the adhesive extends to the surface of the composite fabric.
• 80% to 90%) penetration may be quite acceptable.
• inventive fabrics tend to exhibit harsher qualities after calendering and before washing. Once the inventive fabric is laundered, it expands in thickness after being tightly compressed and exhibits softness and drapability qualities comparable to conventional spunlaced fabrics. If the globules were substantially interconnected, they would tend to make the composite fabric stiffer. The discrete bonding points do not make a continuous film layer in the middle of the fabric but are in discrete globules that neither connect with each other nor penetrate to the surface of the fabric. The surface layers, while hydroentangled enough to interconnect the filaments and maintain surface integrity and strength are, nonetheless free to move enough to give a soft, drapable, flexible material, particularly after washing or mechanical action.
• the two base fabrics may be similar or quite different.
• the base fabrics may differ in basis weight or in fiber composition, construction or a combination of differences.
• the potential binders for the base layers of fabric may be polyethylene, polyamide, polyester, polypropylene and polyvinyl alcohol as well as other potential adhesives. It is preferred that the adhesives be in a thermoplastic state so that the globules may be controlled while being pressed by calender rolls or other arrangement for compressing the base fabrics together.
• the binder be applied in the form of a mesh bonding layer 61, it has been found that it may be applied directly to the underlying base fabric.
• a simple series of adhesive applicators 80 which apply a small amount of binder to the fabric 59.
• the small amount of binder are called drops and form globule type bonds in a manner similar to the dots of the mesh bonding layer 61.
• the arrangement of the drops may not be as uniformly distributed as the dots are in a mesh, however it is believed that the distribution may be close enough to obtain satisfactory lamination while maintaining discrete bonding points or positions to provide the other desirable characteristics.
• the size of the globules is preferably selected or defined so that the adhesive encompasses fibers from both layers of fabric but does not "bleed" through to either surface of the durable fabric.
• the term globule is meant to describe the adhesive material in the fabric although it is probably not spherical. Actually, the globules are quite amorphous being generally flatter and wider because of the nip pressure. It is noted that in some applications where one side of the fabric may be concealed or shielded, the adhesive may be permitted to extend to the surface of that side. However, it is suggested that one of the qualities of the inventive fabric is that the adhesive is not very perceptible at the surface of either side.
• the upper limit on the size of the globules is probably limited by the thickness of the fabric and the lower limit is related to the ability to get the adhesive to encompass fibers in each of the fabric layers.
• the globules will be less than 2 millimeters in diameter and often less than a single millimeter.
• Another consideration of the dots or globules is the spacing. It is believed that the best results when the globules are spaced close to one another. However, it is recognized that a suitable composite fabric may be formed having greater durability than ordinary nonwoven fabrics when the globules are spaced considerably further apart than is preferred.
• the fabric layers may be quite thick in such circumstances or the adhesive may extend to the surface.
• the spacing is about 2 millimeters or less and more preferably about one millimeter or less.
• the activation of the adhesive requires a balance of several considerations. For example, the speed at which the fabrics may be run through the nip will depend on the melting temperature of the adhesive, the temperature of the heated roll, and the pressure at the nip. Other factors may affect the bonding including hardness of the pressure roll, the diameter of the rolls.
• the adhesive in the dots or globules is preferably activated by a heated roller regardless of how the dots are applied to the fabrics.
• Another option with the system to perhaps speed the manufacturing process would be to preheat one or both fabrics so that the calender rolls do not have to heat the fabric from ambient temperature.
• the calender rolls 71 and 72 are arranged so that the lower roll 72 is heated by hot oil or other source of heat and the upper roll 71 provides pressure down onto the heated roll 72.
• the preheaters may be placed in a variety of potential locations as indicated by the numbers 82, 83, 84, and 85 or in any combination that is found acceptable.
• preheating the mesh bonding layer 61 has not been very satisfactory as it tends to melt unevenly and without the two fabrics to hold the dots in place could leave portions without the globules or bonds.
• hydroentangling is not the only nonwoven technology that would benefit by the present invention. Needle punched fabrics which have Z fiber direction arranged by a physical needle punched into a web of randomly oriented fiber also work well within the scope of the present invention. It should also be noted that in some cases it may be desirable under the present invention to bond a nonwoven, a woven, a knit fabric or material made in accordance with technology other than spunlaced or needle punched technology.
• a lightweight knitted fabric combined with a low cost, heavier weight spunlaced fabric as backing for thickness or softness.
• the woven By securing the woven to the nonwoven such that discrete globules of adhesive encase sufficient portions of the fibers from the spunlaced or needle punched nonwoven fabric, the resulting fabric will be durable to multiple launderings.
• a layer of meltable thermoplastic web or mesh such as Delnet® meltable polyethylene web (weight range of 0.2-1.0 oz/yd 2 or 6.8-33.9 g/m 2 with a preferred range of 0.3-0.5 oz/yd 2 or 10.2- 17.0 g/m 2 ) is laid between two layers of spunlaced fabric.
• the fabric layers should be at least 0.6 oz/yd 2 (20.3 g/m 2) up to about 5 oz/yd 2 (170 g/m 2 ) for the heated roll contact fabric of up to 8 oz/yd 2 (271 g/m 2 ) for the "non-preheated" fabric.
• the preferred range is about 0.9-4.0 oz/yd 2 (30.5-136 g/m 2 ).
• the two fabric layers may consist of cellulosics like rayon or lyocell or thermoplastics like polyester or polyamide or blends as desired to create specific sets of properties.
• a preferred blend has been lyocell and MicrosafeTM acetate which gives a permanently antimicrobial absorbent comfort layer.
• the adhesive mesh layer must be sufficiently lower melting than the surface layers to enable reasonable process speeds at a temperature that will not damage the surface layers. It can be, but is not limited to, a condensation polymer or copolymer such as polyamides or polyesters or an addition polymer such as polyethylene or vinyl copolymers. Scrim and surface layer polymers can be selected for reasonable surface energy compatibility to ensure proper adhesion, but with good physical interlock, it is not necessary. It is conceivable to form the globules of the present invention using a punctured or apertured film that under the application of heat would cause discrete bonding points to form. There are probably other techniques that could be used to form the globules.
• the surface fabrics are preferably needled such as by hydroentangling or needle punch, to impart a significant amount of "Z" directionality to the fabrics so that many fibers in the layer are present on both surfaces and fastening them on the inside surface of the layer with the scrim polymer provides stability for the outside surface.
• Other means of web forming for nonwovens result in almost all of the fibers being in the plane of the fabric and not available to hold the outside to the inside.
• Bonding is preferably achieved by use of a heated pressure calender.
• the preferred temperature range is from a low of 300 degrees F (149 degrees C) to enable reasonable process speed to a high of about 450 degrees F (232 degrees C) for thermoplastics like polyesters to about 550 degrees F (288 degrees C) for cellulosics, such as lyocell.
• Pressures should be sufficient to extrude the molten scrim polymer into the surface layers to an extent that will encapsulate a reasonable number of fibers but will not exude to the surface.
• the durable material as made from lyocell nonwoven fabrics is further treated to provide the desired properties.
• Photographs of the "as-made" laminate in Figure 6 show very little fibrillation at lOOx and 250x magnifications. Washing of the material would have been thought to impart absorbency and softness by increasing fibrillation but even after four wash cycles there was little effect on the average fiber size.
• Beck (rope) dyeing, rotary or paddle dyeing with either a direct-type or reactive dye after alkaline scouring there was an extensive amount of fibrillation on the surface. This is shown in the set of photographs in Figure 7.
• microfibers in great numbers which are well anchored in the fabric structure but free enough in most of their length and particularly at the surface of the fabric to act as an outstanding absorbent article.
• This one structure could be the starting point for several products that would benefit from the several microfibers not being tied up in yarns.
• Some concepts include the chamois- type materials, glass cleaner, etc.
• the substrate of a super-suede type fabric in which the fibrils are further fastened by resin such as a polyurethane and raised by brushing or sanding can be achieved. Such materials would have application as non-disposable, yet relatively inexpensive, wearing apparel.
• the top encounters the first water jets, so fibers oriented in the direction of the z-axis may be more abundant. However, the bottom is needled last and encounters more needling energy. Even though the top appears denser (i.e., more stable), from observation the bottom gives the more stable outside surface in the laminated fabric. Speed, pressure and temperature of the hot roll are also relevant to stability.
• the unwind was configured to provide the optimum top to top lamination and the string up before the hot roll was made to give some preheat on top and bottom of the ingoing laminate. Also, a 180 degree wrap on the hot roll before the nip and a 180 degree wrap on the chill roll exiting the nip was employed. With the preferred unwind and string up, and the small temperature and pressure ranges chosen, the items could be made readily with sufficient stability.
• the chamois-type fabric was made from two layers of spunlaced style 8630 bonded with a layer of Delnet 530 according to the process disclosed in US Patent Application 08/642,649 and finished by dyeing in a jet dyer or Beck dyer with a direct dye.
• the 8630 is a 1.25 denier per filament lyocell having a basis weight of 2.3 oz/yd ⁇ and 40 mesh needled. Comparable products can be obtained by paddle or rotary dyeing after alkaline scouring using either direct or reactive dyes..
• Natural (real) chamois is made by oil tanning leather splits.
• Typical artificial chamois is made by polymer treating woven or nonwoven cloth.
• Basis Weight, Thickness and Tensile (Grab Strength and Elongation) measurements are based on ASTM DI 117 measurement methods.
• the Absorbent Capacity and Rate are measured using a Gravimetric Absorbency Tester (GAT), which is available from M&K Systems, wherein the fabric is under an approximately 350 kg per square meter load.
• GAT Gravimetric Absorbency Tester
• the Tl/2 time is the time for the fabric to take up half of its total uptake of water.
• the rate at Tl/2 is the slope of the absorption curve at time Tl/2.
• Intrinsic absorbency (int abs) is a measurement of the amount of water the fabric will absorb as a percentage of the weight of the fabric. Samples of the fabric are fully immersed in water and allowed to drain for approximately one minute. The difference in the dry and wet weight of the sample is divided by the dry weight of the sample and then multiplied by 100 so as to be expressed as a percentage. Wick Rate is measured by the INDA STM 10.1 method.
• inventive fabrics are of comparable or better absorbency and faster wick rate than natural chamois and other artificial chamois-type materials.
• inventive fabrics retain the qualities of a spunlaced nonwoven fabric which include low cost, comfort, drapability, softness, absorbency, breathability among others while having the durability of knitted or woven materials. Additionally, laminates consisting of more than two base fabric layers are possible.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Nonwoven Fabrics (AREA)
• Laminated Bodies (AREA)
• Manufacturing Of Multi-Layer Textile Fabrics (AREA)
• Cleaning Implements For Floors, Carpets, Furniture, Walls, And The Like (AREA)

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• 1998
  • 1998-11-02 CA CA002304963A patent/CA2304963A1/en not_active Abandoned
  • 1998-11-02 JP JP2000519139A patent/JP2001521846A/ja active Pending
  • 1998-11-02 EP EP98957463A patent/EP1029121A1/de not_active Withdrawn
  • 1998-11-02 KR KR1020007004866A patent/KR20010031798A/ko not_active Application Discontinuation
  • 1998-11-02 WO PCT/US1998/023196 patent/WO1999023291A1/en not_active Application Discontinuation
  • 1998-11-17 TW TW087118432A patent/TW487633B/zh active
• 2000
  • 2000-12-07 US US09/731,602 patent/US20010000585A1/en not_active Abandoned

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