EP2471986A1 - Mehrweg-Fliesgewebestruktur - Google Patents

Mehrweg-Fliesgewebestruktur Download PDF

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Publication number
EP2471986A1
EP2471986A1 EP10197394A EP10197394A EP2471986A1 EP 2471986 A1 EP2471986 A1 EP 2471986A1 EP 10197394 A EP10197394 A EP 10197394A EP 10197394 A EP10197394 A EP 10197394A EP 2471986 A1 EP2471986 A1 EP 2471986A1
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EP
European Patent Office
Prior art keywords
web
fabric structure
nonwoven fabric
fibers
needle
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Withdrawn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
EP10197394A
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English (en)
French (fr)
Inventor
Stuart Smith
André Lang
Marc Jolly
Jos Van Hattum
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Norafin Industries (Germany) GmbH
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Norafin Industries (Germany) GmbH
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Filing date
Publication date
Application filed by Norafin Industries (Germany) GmbH filed Critical Norafin Industries (Germany) GmbH
Priority to EP10197394A priority Critical patent/EP2471986A1/de
Publication of EP2471986A1 publication Critical patent/EP2471986A1/de
Withdrawn legal-status Critical Current

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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
    • 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
    • D04H1/48—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 in combination with at least one other method of consolidation
    • D04H1/49—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 in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D04H1/4342—Aromatic polyamides
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • 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

Definitions

  • the present invention relates to a method for manufacturing a multiple-use nonwoven fabric structure for arc flash protection, a multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2 in accordance with NFPA 70E Standard for Electrical Safety in the Workplace.
  • ATPV Arc Thermal Protection Value
  • An electrical arc flash is defined as a condition where electric current passes through ionized gases in the air. It is caused by an electrical fault and results in a dangerous release of intense energy into the space surrounding the electrical equipment.
  • This energy is released as a combination of:
  • Flame retardant clothing is worn as part of the personal protective equipment (PPE) systems used to protect workers who could potentially be exposed to arc flash situations.
  • PPE personal protective equipment
  • Many countries have established government standards which specify the level of performance required with respect to the clothing to be worn. In the USA, the guidelines for arc flash safety in the workplace are specified in NFPA 70E - Standard for Electrical Safety in the Workplace. This standard specifies two methods to determine performance arc flash performance; ASTM F1506 - Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards, and ASTM F1959 - Standard Test Method for Determining the Arc Rating of Materials for Clothing.
  • ATPV Arc Thermal Performance Value
  • HRC Hazard Rating Categories
  • one of the primary methods used to determine arc performance is EN 61482-1-2 - Live Working - Protective Clothing against the Thermal Hazards of an Electric Arc.
  • This method uses two different test currents, 4kA and 7kA, to generate an arc.
  • the current level is chosen according to the class of protection required for the practical usage conditions defined by the customer, tests performed using a 7kA current being more demanding. If the combination of time taken and maximum temperature rise fall below the allowed temperature rise to avoid 2 nd degree burning as defined using STOLL curves, then the material is either rated as Class 1 using a 4kA test current, or Class 2 using a 7kA test current.
  • fully durable, re-usable, or multi-launderable PPE apparel are typically made from traditional textiles such as woven and knitted materials.
  • traditional textiles such as woven and knitted materials.
  • fully durable woven and knitted materials available in the market, however, they fall into two distinct categories.
  • the major disadvantage of current woven materials is that the arc flash performance is heavily dependent on the weight of the material.
  • typically, the most light-weight single layer woven materials available that meet the HRC 2 requirement are approximately 237 g/m 2 , and even at this weight, the ATPV is only between approximately 8.4 and 8.7 Cal/cm 2 (minimum ATPV for HRC 2 is ⁇ 8 Cal/cm 2 ).
  • current materials which meet the requirement of Class 2 have either a minimum basis weight of approximately 400 g/m 2 , or use multiple layers of lighter weight materials to achieve the level of protection.
  • the weight of the material must be further increased.
  • other important performance attributes of the material such as its breathability and permeability and comfort are negatively impacted.
  • An object of the present invention is to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide a method for manufacturing a multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2 in accordance with NFPA 70E Standard for Electrical Safety in the Workplace.
  • ATPV Arc Thermal Protection Value
  • the fire-resistant fibres may be thoroughly opened and blended to ensure a uniform distribution and blend of the fire-resistant fibers before they are formated into the web.
  • the web is formated by preparing a uniform web of fire-resistant fibers, where the fire-resistant fibers within the web are individualised, uniformly blended, and have a uniform weight and density throughout the web.
  • the orientation of the fibers within the web significantly influences the strength and durability of the final fabric structure.
  • the parallel-laid web yields excellent blend uniformity and weight/density distribution
  • the strength properties of the web are not well suited to e.g. apparel applications - it has significantly higher strengths in its length or machine direction, compared to its width or cross machine direction. In apparel applications, it is desirable to have approximately equal strengths in both machine and cross machine directions, both with regard to subsequent processing and the performance of the finished garment.
  • the web may be folded back and forth upon itself to form a web in which the fire-resistant fibers are more equally oriented in both a length direction and a width direction of the web, yielding approximately equal strengths in both directions.
  • the web is cross-laid. Due to the build-up and folding action of multiple web layers, the cross laying system allows for the manufacture of significantly heavier basis weight materials than would be possible if a parallel-laid web was used. Additionally, the width of the material that can be produced is independent of the width of the web formation system.
  • the web may be drafted, or combed, through a series of toothed rollers consisting of multiple sets of 3 roller trios, running at increasing speeds between each trio.
  • toothed rollers consisting of multiple sets of 3 roller trios, running at increasing speeds between each trio.
  • the needle-punching may be performed by penetrating the web with an array of barbed needles that carry tufts of the web's own fire-resistant fibres in a vertical direction through the web. As the needles move through the web, their barbs hook the fibres and interlock them with adjoining fibres.
  • the needle-punching may be performed in two stages, a first pre-needling stage consisting of single-sided needle penetration to initially consolidate the web from web drafting, and subsequently a second needling stage which fully consolidates the web by penetration with needles from both the top and bottom surfaces of the web.
  • the needle penetration and number of needle penetrations play a major role in determining the strength and durability of the final fabric structure.
  • the first pre-needling stage may have a punch density greater than 150 punches/cm 2
  • the second needling stage may have a punch density greater than 300 punches/cm 2 .
  • punch density is meant number of needle penetrations per unit area.
  • nonwoven fabric layer subsequent to the needle-punching may be wound into rolls of a predetermined length.
  • the rolled nonwoven fabric layer may be arranged on a tension-controlled unwind station before the spunlacing step.
  • additional bonding to form the nonwoven fabric structure may be achieved by spunlacing.
  • the nonwoven fabric layer i.e. after the needle-punching step, is then mechanically bonded together using the spunlacing/hydro-entanglement process.
  • the spunlacing process consists of passing the nonwoven fabric layer beneath a series of high pressure, small diameter water jets. As the water jets impinge on the fibres within the nonwoven fabric layer, the individual fibres are moved and interlocked. Mechanical bonding by hydro-entanglement yields fabric structures which are very clean with an appearance that can be modified to be similar to woven materials. It has a minimal effect on the bonded fabric structure, and the fabric structures are therefore soft, drapable, and more comfortable to wear. Also, hydro-entanglement does not damage the fibres within the nonwoven layer during bonding, allowing improved strength, abrasion, and durability performance to be achieved.
  • Hydro-entanglement may be performed by means of a pressure in the range of 20 MPa (200 bars) to 150 MPa (1500 bars). Tests have shown that the pressure level is related to the energy intake of the fabric, and furthermore that the strength of the fabric increases with the pressure increase to a certain limit.
  • nonwoven fabric structure after the hydro-entanglement step, may be placed in a series of vacuum boxes, before being dried in a through-air oven in order to remove excess water and moist from the fabric structure.
  • the nonwoven fabric structure may be chemically after treated, such as coloured, printed, dyed or applied with performance-enhancing chemicals, or a combination thereof.
  • the present invention further relates to a multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2 in accordance with NFPA 70E Standard for Electrical Safety in the Workplace, said multiple-use nonwoven fabric structure comprising a nonwoven layer which comprises fire-resistant fibers, the fire-resistant fibers first being bonded by needle-punching and subsequently by spunlacing.
  • AAV Arc Thermal Protection Value
  • the inherent fibers may be, but are not limited to, FR Viscose, meta-aramid, para-aramid, melamine, Polybenzimidazole (PBI), Silex, Basalt, or a combination thereof.
  • the fibers may have a linear density between 0.5 and 5 dtex and a staple fiber length between 10 and 100 mm.
  • the number of fibers per unit area in the nonwoven part of fabric structure can be optimised to yield a more dense structure contributing to the improved ATPV performance exhibited.
  • the appearance and coverage of the nonwoven fabric structure are improved.
  • Fibers with staple lengths between 10 and 100 mm allow optimum bonding to be achieved during mechanical bonding, positively impacting many fabric characteristics such as strength, wash durability, abrasion resistance, etc.
  • the fabric structure may comprise one or more additional layers, the one or more additional layers being introduced into the fabric structure before the spunlacing bonding.
  • the one or more additional layers may be a dry-laid carded web, a nonwoven layer, a woven layer, a knitted layer, a net/mesh, or a combination thereof.
  • the fabric structure may be dyed and/or printed.
  • the fabric may have a basis weight of 40 to 1000 g/m 2 .
  • the present invention also relates to a garment made of a multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2.
  • AAV Arc Thermal Protection Value
  • the present invention relates to the use of an arc flash protection, multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2 in accordance with NFPA 70E Standard for Electrical Safety in the Workplace for garments, blankets, flash fire PPE, molten metal splash PPE, fire fighters PPE, apparel, awnings, curtains, floor covers, work wear, and military uses.
  • AAV Arc Thermal Protection Value
  • the types, blends, and dimensions of the fire resistant fibers to be used to construct the nonwoven layer of the fabric structure must be determined, the primary criteria for selection being the method used to impart flame retardancy to the fabric structure, which is a prerequisite for, e.g., an arc flash protective fabric, and the reaction of the fibers to high temperatures - while a fiber may be flame retardant, it may still melt in the presence of heat and cause burns to the wearer of the material.
  • the nonwoven fabric structure comprises inherently flame retardant fibers which do not need a chemical aftertreatment to impart flame retardancy.
  • Many types are available, including FR Viscose, meta-aramid, para-aramid, melamine, Polybenzimidazole (PBI), Silex, Basalt, or a combination thereof.
  • the preferred dimensions of the different fiber types are a linear density between 0.5 and 5 dtex and a staple fiber length between 10 and 100 mm.
  • Fig. 1 shows a schematic diagram of a method for manufacturing a multiple-use nonwoven fabric structure having an Arc Thermal Protection Value (ATPV) to fabric basis weight ratio greater than 500 cal/g and being a Hazard Risk Category 2 in accordance with NFPA 70E Standard for Electrical Safety in the Workplace comprising three steps 1, 2, 3.
  • ATPV Arc Thermal Protection Value
  • the first step is to provide a web of inherently fire resistant fibers.
  • This is done by a web formation process 1 where a dry, parallel-laid, web formation system is used to prepare a uniform sheet of fibers, or web, where the fibers within the web are individualized, uniformly blended, and have a uniform weight and density throughout the web.
  • the orientation of the fibers within the web may significantly influence the strength and durability properties of the final material. While the parallel-laid web yields excellent blend uniformity and weight/density distribution, the strength properties of the web are not well suited to apparel applications, since they have significantly higher strengths in the length, or machine direction, compared to the width, or cross machine direction.
  • the carded web may be cross-layed.
  • the second step is to bond the fibers of the web by a needle-punching process 2 to form a nonwoven fabric layer, which is obtained by needling (needle-punching).
  • the needle-punching process 2 may consist of mechanically binding a web to form a fabric layer by penetrating the web with an array of barbed needles that carry tufts of the web's own fibers in a vertical direction through the web. As the needles move through the web, their barbs can hook the fibers and interlock them with adjoining fibers.
  • needle design, barb placement, barb angle, and barb shape which may be tailored to achieve the intended final fabric performance.
  • the needle-punching process 2 may be performed in two stages; a pre-needling stage consisting of single-sided needle penetration to initially consolidate the web from web drafting, and then a secondary needling stage which fully consolidates the web by penetration with needles from both the top and bottom surfaces.
  • the primary process settings are punch density (number of needle penetrations per unit area) and needle penetration and both settings play a major role in determining the strength and durability characteristics of the final fabric structure.
  • the pre-needling punch density may be greater than 150 punches/cm 2 whereas the main needling punch density may be greater than 300 punches/cm 2 .
  • the third step is to bond the nonwoven fabric layer by a spunlacing process 3 to form the nonwoven fabric structure.
  • the spunlacing process 3 bonds the fabric layer mechanically together using the spun-lacing process 3.
  • the basic principle of the spun-lacing process 3 consists of passing the fabric layer beneath a series of high pressure, small diameter water jets. As the water jets impinge on the fibers within the fabric layer, the individual fibers are moved and interlocked.
  • the spun-lacing process 3 is again an entangling step which is performed to entangle the fibers further.
  • the spun-lacing process 3 may be performed by using a water pressure in the range of 20 MPa (200 bars) to 150 MPa (1500 bars).
  • the strength of the fabric structure can be increased to a certain limit by increasing the water pressure, since the water pressure level is related to the energy intake of the fabric structure, which again is related to the strength of the fabric structure.
  • Fig. 2 shows a more detailed schematic diagram of the manufacture of a needle-punched fabric layer.
  • the fibers are thoroughly opened and blended in a fiber opening/blending process 4 using conventional staple fiber preparation equipment to assure a uniform distribution and blend of the selected fiber types in such a form which is suitable for subsequent feeding to a web formation system 1. Up to four individual fiber types may be intimately blended.
  • the next step is to provide a web of inherently fire resistant fibers. This is done by a web formation process 1 as described in the description of Fig. 1 .
  • Multiple types of web formation systems exist. However, the principle of the different systems is essentially the same - to prepare a uniform sheet of the fibers, or web, where the said fibers within the web are individualized, uniformly blended, and have a uniform weight and density throughout the web.
  • the next step is to cross-lay the parallel systems from the preceding step in a cross-laying process 5.
  • Cross-laid systems take a web produced on a parallel system and then fold it back on forth upon itself to form a web in which the fibers are more equally oriented in both the length and width directions.
  • Random web forming systems yield webs that orient the fiber not only in the length and width directions, but also vertically through the web.
  • the orientation of the fibers within the web significantly influences the strength properties of the final material.
  • Parallel-laid webs have significantly higher strengths in the length, or machine direction, compared to the width, or cross direction.
  • Cross-laid webs, as used in the preferred embodiment have approximately equal strengths in the machine and cross machine directions. Due to the build-up and folding action of multiple carded web layers, the cross laying system allows for the manufacture of significantly heavier basis weight materials than would be possible if a carded parallel-laid web was used. Additionally, the width of the material that can be produced is independent of the width of the carding system.
  • the next step helps to further improve fiber uniformity and basis weight distribution.
  • the cross-laid web is drafted, or combed, by a web drafting process 6 through a series of toothed rollers consisting of multiple sets of three roller trios, running at increasing speeds between each trio. Additionally, this effect removes any folds or lapping marks for the previous process.
  • the needle-punching process 2 When the web has been drafted, the web is further processed by the needle-punching process 2 which is also described in the description of Fig. 1 .
  • the needle-punching process 2 may be split into two separate processes; a pre-needling process 21 and a needling process 22.
  • the pre-needling process 21 consists of a single-sided needle penetration to initially consolidate the web from the web drafting process 6, and then a secondary needling process 22 which fully consolidates the web by penetration with needles from both the top and bottom surfaces.
  • needle-punched fabric layer is wound in a winding process 7.
  • the fabric layer may be wound into rolls of a suitable length, and if necessary, cut or slit to a specific width.
  • Fig. 3 shows a more detailed schematic diagram of the manufacture of a spun-laced fabric structure.
  • First step is to unwind the needle-punched fabric layer from the needle-punching process 2 by an unwinding process 8.
  • the unwound fabric layer is subsequently spun-laced in a spun-lacing process 3.
  • the spunlacing process 3 may be carried out on unwound needle-punched fabric layer coming from one or more un-winding processes, depending on how many layers are going to be spun-laced in the same spun-lacing process 3.
  • Different layers may come from various un-winding processes 8 of needle-punched fabric layers or un-winding processes 81 of other materials or directly from the fiber blending/opening process 4 and web formation process 1.
  • the different layers may then subsequently be assembled into a multiple layer fabric structure and spun-laced in the spun-lacing process 3.
  • the excess water may be removed from the material by a drying process 9, e.g. in a through-air oven.
  • the drying process 9 may comprise an additional step of vacuum extraction via a series of vacuum boxes before being dried.
  • spun-laced fabric structure is wound in a winding process 7.
  • the fabric structure may be wound into rolls of a suitable length, and if necessary, cut or slit to a specific width.
  • Fig. 4 shows a more detailed schematic diagram of the manufacture of a final material or final garment.
  • the fabric structure may initially have to be unwound, if the fabric structure was wound in an antecedent process step, before proceeding with an aftertreatment of the fabric structure.
  • the aftertreatment process 10 may comprise several separate processes depending on the performance requirements of the final application.
  • the fabric structure may be subjected to one or more chemical aftertreatment processes which typically, at least as a minimum for apparel applications, include colouring (either a single uniform colour or a multiple colour pattern design).
  • Two primary methods of coloring are dyeing and printing performed using traditional textile finishing equipment.
  • the material can be colored using dyeing or printing or by using both.
  • the types of dyes used are the same as those used for dyeing traditional textiles, which typically depend on the type or types of fibers used. Pigment colouration typically comprise the use of pad, dip, or spray applications. Furthermore, several other types of performance enhancing chemicals can be applied to the fabric structure using traditional textile finishing technology. The types of fabric structure finishes which may be obtained vary significantly, and the aftertreatment processes are therefore tailored to meet the performance requirements of the application and may include processes to enhance: wash durability, abrasion resistance, repellency (water, oils, alcohols), antistaticness, absorbency, softness, etc.
  • the fabric structure may be treated with cross-linking, film forming synthetic binders.
  • the binders may be applied by pad, dip, or spray applications.
  • an acrylic copolymer binder and melamine formaldehyde resin mixture are padded into the fabric structure.
  • a potential final aftertreatment step is a combined process to soften the fabric structure, and reduce the shrinkage which can occur due to repeated launderings during the life of the fabric structure.
  • a commonly known, traditional method of achieving a softer and more shrink-resistant fabric structure is via the process of sanforization, whereby, in the presence of water or steam, the fabric structure is stretched, shrunk, and fixed in the length and width directions.
  • the fabric structure When the fabric structure has been submitted to the relevant aftertreatment processes 10, the fabric structure is wound in a winding process 7 and if necessary cut or slit to a specific width.
  • the aftertreated fabric structure can be converted to a garment by a garment converting process 11.
  • the fabric structure is converted into garments using traditional cut and sew methodologies.
  • the performance of the fabric structures were determined using the standards and requirements identified in ASTM F1959 - Standard Test Method for Determining the Arc Rating of Materials for Clothing, ASTM F 1506 - Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards, and EN 61482-1-2 - Live Working - Protective Clothing against the Thermal Hazards of an Electric Arc.
  • the ATPV performance of the fabric structures as determined by ASTM F1959 - Standard Test Method for Determining the Arc Rating of Materials for Clothing easily exceeds the performance of currently available woven materials in the market when comparing the materials on a weight for weight basis.
  • the different embodiments of the invention have an ATPV to fabric basis weight ratio of greater than 500 cal/g.
  • Currently available woven materials have an ATPV to fabric basis weight ratio ranging from approximately 270 - 370 cal/g.
  • ATPV cal / cm 2 ATPV to Basis Weight Ratio cal / g x Fabric Basis Weight g / m 2 10 , 000
  • the nonwoven fabric structure In addition to ATPV, to be approved for use as an arc flash protective material in the USA, the nonwoven fabric structure must also meet all the requirements of ASTM F 1506 - Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards. When tested in accordance with this standard, the present nonwoven fabric structure meets or exceeds all requirements.
  • the nonwoven fabric structure can meet a Class 1 performance level at a basis weight less than 200 g/m 2 .
  • a Class 2 performance level can be achieved at a basis weight less than 325 g/m 2 - currently available woven materials have basis weights of approximately 400 g/m 2 or higher to achieve this same performance.
  • the thermal mannequin performance of the fabric structure provides an additional important indication of how well a material performs in thermal or fire-related end-uses.
  • EN469 Protective Clothing for Fire Fighters using a 4 sec flame time, many nonwoven fabric structures maintain a total burn of less than 60% through at least 25 washing cycles when washed in accordance with AATCC Method 135 (3, IV, A iii).
  • the nonwoven fabric structure consists of a single layer.
  • the fabric structure is constructed from FR Viscose and p-aramid fibers, the FR Viscose fibers having an average staple length of approximately 51 mm and a linear density of 2.2 dtex, and the p-aramid fibers having an average staple length of approximately 50 mm and a linear density of 1.7 dtex.
  • the said fibers were thoroughly opened and blended in a ratio of 85% FR Viscose and 15% p-aramid using conventional staple fiber preparation equipment to ensure a uniform distribution and blend of the two fiber types in a form suitable for subsequent feeding to the web formation system.
  • the pre-opened and blended fibers were fed into the web formation system, in this case a parallel-laid system.
  • the basis weight of the web formed was approximately 20 g/m 2 .
  • the formed web was cross-lapped into multiple layers to produce an unconsolidated web weight of approximately 140 g/m 2 .
  • the cross-lapped web was then drafted and needle-punched to produce a needle-bonded nonwoven fabric layer of approximately 130 g/m 2 in weight.
  • the nonwoven fabric layer was wound into rolls and mounted in the unwind station in the spun-laced line.
  • the nonwoven fabric layer was then spun-laced to achieve maximum strength, integrity, and durability.
  • the resultant spun-lace nonwoven fabric structure yielded a basis weight of 130 g/m 2 .
  • the nonwoven fabric structure was tested to all parameters defined in ASTM F 1506 -Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards. Actual results are shown in Table 1 in comparison to the requirements of the standard.
  • the minimum performance requirements defined in ASTM F1506 are different - the values in the table below are those defined for woven fabrics between 102 and 200 g/m2 and knitted fabrics between 102 and 271 g/m 2 .
  • the fabric according to Example 1 having a basis weight of 130 g/m2, meets or exceeds all criteria of the standard for knitted as well as for woven fabrics in this weight range.
  • the fabric structure consists of two layers.
  • the fabric structure is constructed from two needle-punched nonwoven fabric layers.
  • Layer 1 is constructed from FR Viscose and p-aramid fibers, the FR Viscose fibers having an average staple length of approximately 51 mm and a linear density of 2.2 dtex, and the p-aramid fibers having an average staple length of approximately 50 mm and a linear density of 1.7 dtex.
  • Layer 2 is constructed from FR Viscose fibers, having an average staple length of approximately 51 mm and a linear density of 2.2 dtex.
  • layer 1 the said fibers were thoroughly opened and blended in a ratio of 85% FR Viscose and 15% p-aramid for using conventional staple fiber preparation equipment to ensure a uniform distribution and blend of the two fiber types in a form suitable for subsequent feeding to the web formation system.
  • the pre-opened and blended fibers were fed into the web formation system, in this case a parallel-laid system.
  • layer 2 100% of FR Viscose fibers were opened using the same system as above.
  • the basis weight of the web formed was approximately 20 gsm.
  • the formed web was cross-lapped into multiple layers to produce an unconsolidated web weight of approximately 80 g/m 2 .
  • the formed web was cross-lapped into multiple layers to produce an unconsolidated web weight of approximately 100 g/m 2 .
  • the cross-lapped web from layer 1 was then drafted and needled to produce a needle-bonded nonwoven fabric layer of approximately 60 g/m 2 in weight.
  • the cross-lapped web from layer 2 was then drafted and needled to produce a needle-bonded nonwoven fabric layer of approximately 70 g/m 2 in weight.
  • Both needle-bonded nonwoven fabric layers were wound into rolls and mounted in the unwind station in the spun-laced line.
  • the minimum performance requirements defined in ASTM F1506 are different - the values in the table below are those defined for woven fabrics between 102 and 200 g/m 2 and knitted fabrics between 102 and 271 g/m 2 .
  • Example 2 having a basis weight of 130 g/m 2 , meets or exceeds all criteria of the standard for knitted as well as for woven fabrics in this weight range.
  • Table 1 Characteristic Test method ASTM F1506 Minimum performance requirements
  • Example 1 Example 2 Basis weight (g/m2) N/A N/A 130 130 Tensile at ASTM 134 min. N/A 317 228 Break (N) D5034 Tear ASTM 11 min. N/A >11 >11 Resistance (N) D1424 Burst Strength ASTM N/A 179 TBD TBD (N) D3786 Seam Slippage ASTM 6 mm max. at 134 N N/A N/A N/A D434 Colourfastness Laundering AATCC Class 3 min.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
EP10197394A 2010-12-30 2010-12-30 Mehrweg-Fliesgewebestruktur Withdrawn EP2471986A1 (de)

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CN108823789A (zh) * 2018-06-28 2018-11-16 贵州省湄潭县卓越千层棉胎制品有限公司 一种无网被及其加工方法
CN114575033A (zh) * 2021-12-21 2022-06-03 陕西华特新材料股份有限公司 一种玻璃纤维混合针刺毡及其制作方法

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CN104328602A (zh) * 2014-12-02 2015-02-04 福建南纺股份有限公司 一种复合海岛纤维合成革基布及其制备方法
CN104328602B (zh) * 2014-12-02 2015-08-12 福建南纺有限责任公司 一种复合海岛纤维合成革基布及其制备方法
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CN114575033A (zh) * 2021-12-21 2022-06-03 陕西华特新材料股份有限公司 一种玻璃纤维混合针刺毡及其制作方法

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