EP4036296A1 - Elastic nonwoven fabric and method of making the same - Google Patents

Elastic nonwoven fabric and method of making the same Download PDF

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Publication number
EP4036296A1
EP4036296A1 EP22153194.0A EP22153194A EP4036296A1 EP 4036296 A1 EP4036296 A1 EP 4036296A1 EP 22153194 A EP22153194 A EP 22153194A EP 4036296 A1 EP4036296 A1 EP 4036296A1
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EP
European Patent Office
Prior art keywords
fibers
nonwoven
range
nonwoven fabric
process according
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.)
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Application number
EP22153194.0A
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German (de)
English (en)
French (fr)
Inventor
Mauro Davanzo
Sarah Ziem
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Carl Freudenberg KG
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Carl Freudenberg KG
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Publication date
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Publication of EP4036296A1 publication Critical patent/EP4036296A1/en
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • 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
    • D04H1/50—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 treatment to produce shrinking, swelling, crimping or curling of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—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
    • D04H1/52—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 applying or inserting filamentary binding elements
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C7/00—Heating or cooling textile fabrics

Definitions

  • the present invention relates to a nonwoven fabric having a special structure which gives it elastic properties, to a process for its production and to its use for thermal and/or acoustic insulation and for the production of textile articles, in particular for thermally insulating clothing.
  • Nonwovens for thermal insulation in the textile sector e.g. for sports and outdoor clothing.
  • the desired property profile is complex and, in addition to pure insulation quality, includes requirements for high wear comfort, care and other material properties. These include high thermal insulation, good moisture management, i.e. the ability to absorb perspiration from the skin and release it into the environment, good drying properties and good insulating properties even when soaked, good washability and resistance to fiber migration, high wearing comfort, good haptic properties (softness), etc.
  • the demand for nonwovens is particularly high. In particular, there is a need for nonwovens for wadding that have two actually contradictory properties: high thermal insulation, especially when the wearer is not active, and good air permeability, high breathability and the ability to remove excess heat when the wearer is active.
  • EP 0390579 A1 describes a lightweight, insulating, stitch-bond nonwoven fabric and a method for its manufacture. According to this, a nonwoven fiber layer is stitched under tension with a plurality of needles using an elastic thread, the tension is released after stitching, and the nonwoven fabric thus stitch-bond is subjected to a shrinkage treatment at a temperature in a range of 50 to 100 °C. In this way, the bonded fiber layer is drawn together or crimped and the specific volume of the textile fabric is increased. In this process, shrinkage is produced mainly in the longitudinal direction of the nonwoven fabric, i.e. in the machine direction (md).
  • EP 0695382 A1 describes a process for the production of a gathered nonwoven fabric, in which the fiber layer is made dimensionally stable and wash-resistant by overstitching the gathered fiber layer with inelastic yarn. The result is a nonwoven fabric which has rows of corrugations or bulges and which has an extensibility in the longitudinal and transverse direction of at most 20 %.
  • EP 0303497 A2 describes a layer of substantially nonbonded fibers which is multi-needle stitched with elastic thread to form a nonwoven fabric. This causes contraction and drawing together of the nonwoven fabric surface, wherein the nonwoven fabric area after release of the tension force is not greater than 40 % of the initial area of the fiber layer.
  • the oject of the present invention is to provide a nonwoven fabric for thermal and acoustic insulation and wadding based thereon, which has good application properties and, in particular, good clothing physiological properties, especially for use in sports and outdoor clothing.
  • a first object of the invention is to provide a process for the production of a nonwoven fabric comprising the steps of
  • a Raschel process is used for the knitting in step ii).
  • Another object of the invention is a nonwoven fabric obtainable by a process as previously and hereinafter defined.
  • Another object of the invention is a nonwoven fabric comprising a nonwoven fibrous material bonded by incorporating a yarn capable of thermal shrinkage by knitting with a plurality of needles and having parallel rows of zig-zag stitches and rows of corrugations arranged substantially in the longitudinal direction (md), the crests and troughs of the corrugations being arranged substantially parallelly to the longitudinal direction (cmd) of the nonwoven fabric.
  • Another object of the invention is a thermally insulating wadding comprising or consisting of a nonwoven fabric as previously and hereinafter defined or obtainable by a process as previously and hereinafter defined.
  • Another object of the invention is a textile article comprising a nonwoven fabric as previously and hereinafter defined or obtainable by a process as previously and hereinafter defined, or comprising a thermally insulating wadding as previously and hereinafter defined.
  • Another object of the invention is the use of a nonwoven fabric as previously and hereinafter defined, or obtainable by a process as previously and hereinafter defined, or a thermally insulating wadding as previously and hereinafter defined, for the production of a textile article.
  • Another object of the invention is the use of a nonwoven fabric as previously and hereinafter defined or obtainable by a process as previously and hereinafter defined, or a thermally insulating wadding as previously and hereinafter defined, for thermal and/or acoustic insulation
  • the nonwoven fabrics according to the invention are particularly suitable for use in wadding for textile articles, such as sports and outdoor clothing.
  • the nonwoven fabrics according to the invention are also suitable overall for thermal and/or acoustic insulation, e.g. of buildings, vehicles, technical installations and household devices.
  • the x-axis indicates the direction of greatest expansion or longitudinal direction and the y-axis, which is orthogonal to it, indicates the transverse direction. Due to the manufacturing process, nonwoven fabrics in the longitudinal direction as the direction of material flow through the machine used for production (i.e. in the direction of the x-axis, also described as roll direction, machine direction or md) often have different material properties than in the cross direction (i.e. in the direction of the y-axis, also described as counter roll direction, cross machine direction or cmd).
  • the nonwoven fabrics according to the invention have an advantageous three-dimensional structure, which is achieved by the production process according to the invention, especially the combination of a zig-zag stitch binding with a yarn capable of thermal shrinkage and a subsequent shrinkage treatment.
  • the specification of extensibility specifies the ability of the nonwoven fabric to change its shape when a force is applied.
  • the extensibility indicates how far the nonwoven fabric can be extended in a certain direction without tearing.
  • the nonwoven fabrics of the invention are generally elastic, i.e. reversibly deformable. When the applied force is removed, the nonwoven fabric returns to its original shape.
  • the nonwoven fabrics according to the invention show a permanent change in length after elongation which is at most 15 %, preferably at most 10 %, in particular at most 5 %, especially at most 2 % of the maximum change in length during elongation.
  • the nonwoven fabrics according to the invention have a regular corrugated structure, with the corrugation crests and troughs arranged substantially parallelly to the longitudinal direction (cmd) of the nonwoven fabric.
  • all points on a straight line parallel to the x-axis have the same thickness. All points on a straight line, parallel to the y-axis, have variable thicknesses, corresponding to crests and troughs.
  • a nonwoven material is provided.
  • a fiber composition can be subjected to a conventional process for producing a fiber web (nonwoven formation process) and, if necessary, to one or more subsequent steps for nonwoven fabric production.
  • Suitable processes for the production of nonwovens and nonwoven fabrics are known to those skilled in the art and are described, for example, in H. Fuchs, W. Albrecht, Vliesstoffe, 2nd ed. 2012, p. 121 ff, Wiley-VCH . These include, for example, dry processes, wet processes, extrusion processes and solvent processes.
  • a fiber composition may be provided and subjected to a dry-laying process to produce a fiber web.
  • the production of dry laid nonwovens can in principle be carried out by a carding process or by an aerodynamic process. After the carding process, a fiber web is formed by means of card, whereby the nonwoven can be laid in various ways.
  • the carded fibers are laid parallelly in machine direction, which usually results in different properties in machine direction (md) and in cross direction (cmd) of the fiber nonwoven material.
  • the fiber web which is initially oriented in the machine direction, is doubled several times and in a crosswise manner with the aid of a crosslapper, as a result of which the properties of the nonwoven material in machine direction (md) and in the cross direction (cmd) are generally aligned.
  • nonwovens are formed with the aid of air.
  • fibers are conveyed to a rapidly rotating roll with the aid of an air stream, separated and laid down randomly to form a nonwoven fabric by the centrifugal force with an additional air stream.
  • fiber webs can be stacked in several layers to form a nonwoven.
  • the properties can be modified, e.g. by stretching the nonwoven.
  • a nonwoven can be subjected to thickness calibration and/or prebonding.
  • the usual calendering processes, for example, are suitable for this purpose.
  • the nonwoven material provided in step i) may be a nonwoven material for the production of which a nonwoven has been subjected to mechanical, thermal and/or chemical nonwoven bonding.
  • a nonwoven material which comprises a nonwoven material bonded with a binder or which consists of a nonwoven material bonded with a binder
  • the nonwoven material preferably has a mass per unit area in the range from 10 g/m 2 to 200 g/m 2 , particularly preferably from 20 g/m 2 to 150 g/m 2 .
  • the nonwoven material preferably has a width (extension in the y-direction) of 50 mm to 2500 mm, particularly preferably 900 mm to 2000 mm.
  • the nonwoven material provided in step i) is coiled onto a roll. It can thus be fed to the binding in step ii) by knitting or stitching.
  • the nonwoven material provided in step i) may comprise fibers and fiber blends in general, as used in the production of nonwovens and nonwoven fabrics.
  • the nonwoven material comprises fibers selected from natural fibers, man-made fibers of natural polymers, man-made fibers of synthetic polymers, and mixtures thereof.
  • Suitable natural fibers are selected from plant based fibers, animal fibers and blends thereof.
  • Plant based fibers include, for example, cotton, linen (flax), jute, sisal, coir, hemp, bamboo, etc.
  • Animal fibers include, for example, wool, silk and animal hair, e.g. alpaca, llama, camel, angora, mohair, cashmere, etc.
  • Suitable natural fibers are also those usually employed in paper pulps.
  • the nonwoven material provided in step i) may comprise further fibers comprising or consisting of at least one natural polymer.
  • the natural polymers are selected from chitin, chitosan, plant proteins, keratin and mixtures thereof.
  • the nonwoven material provided in step i) may further comprise man-made cellulose fibers (industrially produced cellulose fibers).
  • man-made cellulose fibers industrially produced cellulose fibers.
  • non-derivatized cellulose fibers also referred to as cellulose regenerated fibers
  • cellulose regenerated fibers are obtained when the solid cellulose, which is in the form of cellulose pulp, is first dissolved and then subjected to fiber formation with re-solidification.
  • cellulose regenerated fibers are produced by a direct solvent process using a tertiary amine oxide as solvent.
  • NMMO N-methyl-morpholine-N-oxide
  • Lyocell fibers produced in this way are given the generic name Lyocell by BISFA (The International Bureau for the Standardisation of Man Made Fibres). Lyocell fibers are offered in a wide range of finenesses by the company Lenzing AG under the brand name Tencel ® .
  • the nonwoven material provided in step i) may further comprise fibers selected from polyester fibers, polyamide fibers, polyurethane fibers, polyolefine fibers, polyacrylic ester fibers, polyacrylonitrile fibers, preoxidized polyacrylonitrile fibers (PAN), carbon fibers, polyvinyl alcohol fibers, polypropylene sulfide fibers (PPS), polyaramide fibers, polyamide imide fibers, thermoplastic starch fibers, man-made cellulose fibers, e.g. viscose, lyocell, cellulosic natural fibers, fibers of natural polymers different therefrom, polyesteramide fibers, glass fibers and mixtures thereof.
  • fibers selected from polyester fibers, polyamide fibers, polyurethane fibers, polyolefine fibers, polyacrylic ester fibers, polyacrylonitrile fibers, preoxidized polyacrylonitrile fibers (PAN), carbon fibers, polyvinyl alcohol fibers, polypropylene sulfide fibers
  • the fibers used in step i) comprise fibers of synthetic polymers, in particular fibers of polyesters, especially polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate, natural fibers, in particular fibers of wool, cotton or silk, mixtures thereof and/or mixtures with other fibers.
  • synthetic polymers in particular fibers of polyesters, especially polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate, natural fibers, in particular fibers of wool, cotton or silk, mixtures thereof and/or mixtures with other fibers.
  • the fibers used in step i) comprise at least one polyester or consist of at least one polyester.
  • the polyesters are selected from aliphatic polyesters, aliphatic-aromatic copolyesters and mixtures thereof.
  • the aliphatic polyesters are selected from polylactic acid (PLA), poly(ethylene succinate) (PES), poly(butylene succinate) (PBS), poly(ethylene adipate) (PEA), poly(butylene succinate-co-butylene adipate) (PBSA), polyhydroxyacetic acid (PGA), poly(butylene succinate-co-butylene sebacate) (PBsu-co-BSe), poly(butylene succinate-co-butylene adipate) (PBSu-co-bad), poly(tetramethylene succinate) (PTMS), polycaprolactone (PCL), polypropriolactone (PPL), poly(3-hydroxybutyrate) (PHB), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), and mixtures thereof.
  • PLA polylactic acid
  • PES poly(ethylene succinate)
  • PBS poly(butylene succinate)
  • PBSA poly(butylene succinate-co-butylene a
  • Preferred polyesters are also aliphatic-aromatic copolyesters (AAC), i.e. polyesters containing at least one aromatic dicarboxylic acid, at least one aliphatic diol and at least one further aliphatic component incorporated. Said other aliphatic component is preferably selected from aliphatic dicarboxylic acids, hydroxycarboxylic acids, lactones and mixtures thereof.
  • AAC aliphatic-aromatic copolyesters
  • the aliphatic-aromatic copolyesters (AAC) are generally biodegradable and/or compostable.
  • the aliphatic-aromatic copolyesters are selected from copolyesters of 1,4-butanediol, terephthalic acid and adipic acid (BTA), copolyesters of 1,4-butanediol, terephthalic acid and succinic acid, copolyesters of 1,4-butanediol, terephthalic acid, isophthalic acid, succinic acid and lactic acid (PBSTIL).
  • PETG polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PEIP polyethylene isophthalate
  • PETG glycol-modified polyethylene terephthalate
  • CHDM 1,4-cyclohexanedimethanol
  • the fibers used in step i) comprise polyester fibers or consist of polyester fibers, in particular they comprise recycled polyester fibers or consist of recycled polyester fibers.
  • the fibers used in step i) preferably comprise at least one polyamide or consist of at least one polyamide.
  • the polyamide fibers are selected from aliphatic polyamines.
  • the aliphatic polyamide is selected from PA 6, PA 6.6, PA 11, PA 12, PA 46, PA 66, PA 666, PA 69, PA 610, PA 612, PA 96, PA 99, PA 910, PA 912, PA 1212, copolymers and mixtures thereof, especially PA 6, PA 6.6 and mixtures thereof.
  • the fibers used in step i) preferably comprise at least one polypropylene or consist of at least one polypropylene.
  • fibers obtained from a polymer blend are used in step i).
  • the fibers used in step i) comprise at least one polyesteramide or consist of at least one polyesteramide.
  • the fibers used in step i) comprise at least one multicomponent fiber.
  • Suitable multicomponent fibers comprise at least two polymer components.
  • Suitable polymers are selected from the polymer components of the aforementioned man-made cellulose fibers, the polymer components of fibers different therefrom, and combinations thereof.
  • Preferred are multicomponent fibers consisting of two polymer components (bicomponent fibers).
  • Suitable types of bicomponent fibers are sheath/core fibers, side-by-side fibers, islands-in-the-sea fibers and pie piece fibers.
  • a preferred bicomponent fiber contains two polymer components selected from two different polyesters. Particularly preferred are the two different polyesters selected from polylactic acid (PLA), poly(ethylene succinate) (PES), poly(butylene succinate) (PBS), poly(ethylene adipate) (PEA), poly(butylene succinate-co-butylene adipate) (PBSA), polyhydroxyacetic acid (PGA), poly(butylene succinate-co-butylene sebacate) (PBsu-co-BSe), poly(butylene succinate-co-butylene adipate) (PBSu-co-bad), poly(tetramethylene succinate) (PTMS), polycaprolactone (PCL), polypropriolactone (PPL), poly(3-hydroxybutyrate) (PHB), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), and mixtures thereof.
  • PPA polylactic acid
  • PES poly(ethylene succinate)
  • PBS poly(butylene succinate)
  • a special bicomponent fiber is a PLA/PBS bicomponent fiber, more specifically a PLA/PBS sheath/core bicomponent fiber, even more specifically a PLA/PBS sheath/core bicomponent fiber with PBS sheath and PLA core.
  • Another special bicomponent fiber is a PTT (polytrimethylene terephthalate) / PET (polyethylene terephthalate) fiber.
  • bicomponent fibers contain at least one polymer component selected from the polyester as defined above and at least one polymer component selected from polyamides.
  • Suitable polyamides are aliphatic polyamines.
  • the aliphatic polyamide is selected from PA 6, PA 6.6, PA 11, PA 12, PA 46, PA 66, PA 666, PA 69, PA 610, PA 612, PA 96, PA 99, PA 910, PA 912, PA 1212, copolymers and mixtures thereof.
  • the fibers used can be characterized by their fineness, i.e. the weight in relation to a certain length.
  • the nonwoven fiber material provided in step i) comprises fibers having a fineness in the range of 0.5 to 10 dtex or consists of fibers having a fineness in the range of 0.5 to 10 dtex.
  • the nonwoven fiber material provided in step i) comprises fibers having a fineness in the range of 0.5 to 6.6 dtex or consists of fibers having a fineness in the range of 0.5 to 6.6 dtex.
  • the nonwoven material provided in step i) comprises synthetic fibers having a fineness in the range of 0.5 to 6.6 dtex or consists of synthetic fibers having a fineness in the range of 0.5 to 6.6 dtex.
  • the nonwoven material provided in step i) comprises synthetic fibers selceted from staple fibers having a fiber length in the range of 10 mm to 70 mm, more preferably 30 mm to 65 mm.
  • step ii) of the process according to the invention the nonwoven material provided in step i) is subjected to binding by incorporating a yarn by means of knitting with a plurality of needles, forming parallel rows of zig-zag stitches.
  • a warp knitting process is used for the knitting in step ii), preferably a stitch knitting process or Raschel process.
  • Equipment known under the designations Maliwatt, Kunit, Malinit, etc. can be used.
  • a Raschel process is particularly preferred.
  • These warpknitting technologies have in common that they can insert a yarn in a zig-zag pattern into a nonwoven.
  • the binding is defined by means of needle offset of the needle bars, e.g. tricot, satin, velvet.
  • Preferred is a binding of the tricot open type, tricot closed type, satin open type, satin closed type or velvet closed type.
  • Especially preferred is a binding of the velvet closed type.
  • the parallel rows of stitches have a row spacing in the range of 1 to 7 rows per centimeter, more preferably in the range of 2 to 4 rows per centimeter.
  • the stitch spacing in each row is in a range of 1 to 4 stitches per centimeter, more preferably in a range of 2 to 3 stitches per centimeter.
  • thermo shrinkable yarns used in step ii) are e.g. based on polyesters, polyamides, viskose, Lyocell, wool, etc.
  • thermo shrinkable yarn used in step ii) comprises at least one polyester or consists of at least one polyester, in particular selected from polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, polylactic acid and copolyester and mixtures thereof.
  • the at least one yarn used in step ii) is selected from yarns containing polyethylene terephthalate fibers or consisting of polyethylene terephthalate fibers.
  • the at least one yarn used in step ii) is selected from multifilament yarns, preferably multifilament yarns comprising 20 to 150 filaments, in particular multifilament yarns comprising 25 to 120 filaments.
  • the at least one yarn has a thermal shrinkage at 200 °C, determined according to DIN EN 14621:2006-03 of from 5.0 % to 15.0 %, preferably from 7.0 % to 10.0 %.
  • the at least one yarn has a maximum tensile elongation, determined according to DIN EN ISO 2062:2010-04, of 10.0 % to 50.0 %, preferably of 17.0 % to 27.0 %.
  • the at least one yarn has a crimp, determined according to DIN 53830-4:1981-05, of from 35.0 % to 55.0 %, particularly preferably from 41.0 % to 51.0 %.
  • the yarns may be subjected to a mechanical pre-treatment e.g. by texturing in particular by crimping.
  • step iii) of the process according to the invention the bonded nonwoven material obtained in step ii) is subjected to a thermal shrinkage treatment at a temperature of at least 100 °C.
  • the bonded nonwoven material is subjected to a thermal shrinkage treatment at a temperature in the range from 120 to 250 °C, particularly preferably from 140 to 220 °C.
  • the duration of the thermal treatment is preferably from 10 seconds to 120 minutes, more preferably from 30 seconds to 60 minutes, in particular from 1 minute to 60 minutes.
  • the thermal treatment can be carried out inline with the production of the bonded nonwoven fiber material or separately from it.
  • the heating of the bonded nonwoven fiber material can preferably be carried out by means of hot air, by bringing it into contact with a heated surface, by means of steam or a combination thereof.
  • a skilled person is familiar with these processes.
  • the bonded nonwoven material is passed through an oven for thermal shrinkage treatment.
  • the temperature is, for example, in a range from 120 to 220 °C at a web speed of 1 to 30 m/min, preferably 2 to 25 m/min.
  • the residence time in the oven is preferably in the range from 30 seconds to 30 minutes.
  • the bond nonwoven material is treated with steam for thermal shrinkage treatment.
  • the treatment time is preferably 30 seconds to 30 minutes.
  • the bond nonwoven fiber material is brought into contact with at least one heating roll for thermal shrinkage treatment.
  • This process is preferably suitable for inline thermal shrinkage treatment following the binding of the nonwoven material in step ii).
  • a further object of the invention is the nonwoven fabric obtainable by the process according to the invention.
  • thermoshrink results in a three-dimensional nonwoven structure in the sense of a regular corrugated structure.
  • the thickness of the nonwoven according to DIN EN ISO 9073-2 (extension in z-axis, i.e. the amplitude of the corrugation) is preferably in a range from 1.2 to 10 mm, particularly preferably from 1.5 mm to 8 mm, especially from 2 mm to 5 mm.
  • the nonwoven fabric according to the invention has a basis weight in the range of 20 to 200 g/m 2 .
  • the nonwoven fabric according to the invention has an extensibility in the transverse direction (cmd) in the range of 90 to 120 %.
  • the nonwoven fabric according to the invention has an extensibility in the machine direction (md) in the range of 20 to 60 %, determined according to DIN EN 29073-3:1992-08.
  • the nonwoven fabric according to the invention has rows of corrugations arranged essentially in the transverse direction (cmd).
  • the material thickness in the region of the crests of the corrugations (in the direction of the z-axis) is preferably in a range from 2 to 7 mm.
  • the material thickness in the area of the corrugation troughs is preferably in a range of 0.2 to 2.0 mm.
  • the nonwoven fabric according to the invention is advantageously suitable for the production of waddings (linings) which can be used as a thermally insulating material in various textile articles.
  • Another object of the invention is a thermally insulating wadding comprising or consisting of a nonwoven fabric as previously defined.
  • the wadding according to the invention comprises at least one binder.
  • the treatment with a binder can be carried out during and/or after the provision of the nonwoven fiber material in step i).
  • the web can be sprayed or impregnated with at least one binder after it has been deposited from the card.
  • the treatment with a binder can also be carried out after step ii), i.e. after the knitted binding.
  • the treatment with a binder is carried out before the thermal treatment in step iii).
  • the thermal insulating wadding according to the invention preferably comprises the at least one binder in an amount of from 1 to 30 % by weight, preferably from 2 to 25 % by weight, based on the total weight of the wadding.
  • the binder used to produce the wadding according to the invention is preferably selected from binders of the acrylate, styrene acrylate, ethylene vinyl acetate, butadiene acrylate, SBR, NBR and/or polyurethane type.
  • the wadding according to the invention is characterized by very good thermal insulation and moisture management.
  • the wadding according to the invention can be subjected to at least one further treatment by a chemical process and/or physical (mechanical and/or thermal) process.
  • this treatment is selected from spray application of a binder material, addition of thermoplastic binders to the fiber blend, sandwich structuring of the wadding, treatment with a textile additive to modify the hydrophilic/hydrophobic properties, and combinations thereof.
  • binder fibers refers to thermoplastic synthetic fibers which, compared with other fibers present in the fiber blend, either can be melted at all or have a melting point at least 1 °C lower than that of the other thermoplastic fibers present in the fiber blend.
  • the binder fibers Preferably, the binder fibers have a melting point at least 5 °C, and more preferably at least 10 °C, lower than the other fibers contained in the fiber blend. This ensures good selective thermal bonding.
  • Bicomponent binding fibers consist of two different polymers, the melting point of one polymer preferably being at least 5 °C, and more preferably at least 10 °C, higher than that of a second polymer also present in the fibers. These polymers are preferably present as a core/sheath structure, with the material of the core having the higher melting point and the material of the sheath having the lower melting point. Also suitable are "side by side” fibers or "sea-island type” fibers. Bicomponent binder fibers with a core/sheath structure are preferred. These include, for example, bicomponent fibers in which the sheath is made of polyethylene and the core of polypropylene.
  • Sandwich-structured means that the wadding comprises at least two nonwoven layers.
  • the sandwich-structured nonwoven material can consist of 2, 3, 4, 5 or 6 layers.
  • a nonwoven material composed of layers can also be considered a nonwoven composite.
  • the individual layers may have the same structure, or two layers may differ in each case in at least one physical and/or chemical property. This includes, for example, the type of fibers, in the case of fiber blends, their composition, the fineness of the fibers, etc.
  • the layers can be bond by conventional methods, e.g. needling, sewing, bonding, laminating, etc.
  • the wadding according to the invention can be subjected to a treatment with a textile additive to modify the hydrophilic/hydrophobic properties.
  • the textile article is preferably selected among clothing articles. These specifically include outerwear, functional sportswear, outdoor clothing, lightweight sports jackets, walking jackets, ski jackets, ski pants, children's clothing, workwear, uniforms, footwear and gloves. Further, the textile articles may be sleeping bags.
  • Another object of the invention is to use a nonwoven fabric as previously defined or obtainable by a process as previously defined or a thermal insulating padding as previously defined for thermal and/or acoustic insulation.
  • the nonwovens and waddings according to the invention are advantageously suited for thermal insulation, for example for insulation systems for use in the construction industry, e.g. for insulating ceilings, roofs, floors, walls and other building surfaces. They are also suitable for insulating various building materials, such as pipes, roller shutter boxes and window profiles, technical equipment, such as heating systems, or household devices.
  • the nonwovens and waddings according to the invention are also advantageously suited for acoustic insulation, e.g. of buildings, automobiles, technical equipment, household devices, etc.
  • the acoustic insulation can be based on sound proofing or acoustic treatment.
  • Sound insulation impedes the propagation of sound by placing an obstacle in the path of the propagating sound wave front, the surface of which is such that sound waves are reflected particularly well. Sound insulation serves to acoustically isolate rooms from unwanted noise from neighbouring rooms or from outside.
  • Sound attenuation or sound absorption reduces the sound energy by partially converting it into another form of energy (e.g. heat) or by absorbing it. This leads to a specific change in the sound of the room, less reverberation and better room acoustics.
  • the principle of sound damping is often used to reduce noise, whereby the sound waves come into contact with structured and/or porous surfaces.
  • EP 3375602 A1 describes sound-absorbing textile composites comprising a) an open-pored carrier layer comprising coarse staple fibers with a linear density of 3 to 17 dtex and fine staple fibers with a linear density of 0.3 to 2.9 dtex, and b) a flow layer arranged on the carrier layer and comprising a microporous foam layer. These composites are used specifically for sound absorption in automotive applications. Reference is made here to the acoustic insulation options described in this document.
  • Figure 1 depicts a nonwoven fabric according to the invention having a regular corrugated structure, with the corrugation crests and troughs arranged substantially in cross machine direction (cmd) of the nonwoven fabric. Shown is a structure in a rest phase, i.e. a phase wherein the wearer is not in action.
  • the nonwoven fabric contracts, becomes voluminous and the air trapped in the structure acts as an air cushion, increasing the thermal insulating effect.
  • Figure 2 depicts the change in the structure of the nonwoven fabric when the wearer is active.
  • the nonwoven fabric expands and excess heat can be removed by means of the "pump effect" induced by the movement.
  • Figure 3 is a side view showing the crests and troughs of the corrugations of the nonwoven fabric.
  • a wadding based on a carded recycled polyester fibre blend was employed, which, based on the total weight, contained 40 % fibres with a fineness of 1.7 dtex and a cut length of 38 millimetres and 60 % fibres with a fineness of 3.3 dtex and a cut length of 64 millimetres.
  • Binding is performed by means of a spray binder being applied on both sides. Curing of the binder and consolidation are effected in an oven using hot air. The binder accounts for 35 % of the total weight of the wadding.
  • the weight per unit area at the end of the nonwoven process is 45 g/m 2 with a roll width at the winder of 190 cm.
  • the nonwoven is fed into a Raschel machine (Kettenwirkmaschine RS 2-V, Karl Mayer Textilmaschinenfabrik, DE-Obertshausen) as a roll material having a width of 190 cm.
  • Raschel machine Karl Mayer Textilmaschinenfabrik, DE-Obertshausen
  • Trevira PET filament yarns consisting of 35 filaments, are incorporated into the nonwoven by a lateral offset of the needle bar and reinforce the nonwoven with a velvet closed binding.
  • a stitch length of 0.33 cm (3 stitches / cm) with a division of 4.5 needles / 25 mm is obtained. This corresponds to a quantity of 4 % filament yarn per square meter.
  • the filament yarn is processed under tension.
  • the velocity of the machine is 4 m / min, corresponding to 1200 strokes per minute.
  • the nonwoven having a total width of 185 cm, is pulled off and wound up and afterwards led through a steamer at 15 m / min and treated with 500 kg steam per hour.
  • the total width of the resulting fiber-enforced nonwoven is 155 cm.
  • a wadding based on a carded recycled polyester fiber blend was employed, which, based on the total weight, contained 95 % polyester fibres and 5 % polyamide fibers. Binding is performed by means of a spray binder being applied on both sides. Curing of the binder and consolidation is effected in an oven using hot air. The binder accounts for 35 % of the total weight of the wadding.
  • the weight per unit area after winding is 50 g/m 2 with a roll width at the winder of 150 cm.
  • the nonwoven is fed into a Raschel machine (Kettenwirkmaschine Raschel Gauge: E18, Karl Mayer Textilmaschinenfabrik, DE-Obertshausen) as a roll material having a width of 150 cm.
  • a Raschel machine Karl Mayer Textilmaschinenfabrik, DE-Obertshausen
  • Trevira PET filament yarns consisting of 35 filaments, are incorporated into the nonwoven by a lateral offset of the needle bar and reinforce the nonwoven with a velvet closed binding.
  • a stitch length of 0.33 cm (3 stitches / cm) with a division of 4.5 needles / 25 mm is obtained. This corresponds to a quantity of 4 % filament yarn per square meter.
  • the filament yarn is processed under tension.
  • the velocity of the machine is 4 m / min, corresponding to 1200 strokes per minute.
  • the nonwoven having a total width of 145 cm, is pulled off and wound up and afterwards led through a steamer at 15 m / min and treated with 500 kg steam per hour.
  • the total width of the resulting fiber-enforced nonwoven is 130 cm.
  • a wadding based on a carded recycled polyester fiber blend was employed, which, based on the total weight, contained 100 % polyester fibres. Binding is performed by means of a spray binder being applied on both sides. Curing of the binder and consolidation is effected in an oven using hot air. The binder accounts for 23 % of the total weight of the wadding.
  • the weight per unit area after winding is 70 g/m 2 with a roll width at the winder of 150 cm.
  • the nonwoven is fed into a Raschel machine (Kettenwirkmaschine Raschel Gauge: E18, Karl Mayer Textilmaschinenfabrik, DE-Obertshausen) as a roll material having a width of 150 cm.
  • a Raschel machine Karl Mayer Textilmaschinenfabrik, DE-Obertshausen
  • Trevira PET filament yarns consisting of 35 filaments, are incorporated into the nonwoven by a lateral offset of the needle bar and reinforce the nonwoven with a velvet closed binding.
  • a stitch length of 0.5 cm (2 stitches / cm) with a division of 4.5 needles / 25 mm is obtained. This corresponds to a quantity of 1.5 % filament yarn per square meter.
  • the filament yarn is processed under tension.
  • the velocity of the machine is 4 m / min, corresponding to 1200 strokes per minute.
  • the nonwoven having a total width of 145 cm, is pulled off and wound up and afterwards led through a steamer at 15 m / min and treated with 500 kg steam per hour.
  • the total width of the resulting fiber-enforced nonwoven is 130 cm.
  • a wadding based on a carded recycled polyester fiber blend was employed, which, based on the total weight, contained 100 % polyester fibres. Binding is performed by means of a spray binder being applied on both sides. Curing of the binder and consolidation is effected in an oven using hot air. The binder accounts for 23 % of the total weight of the wadding.
  • the weight per unit area after winding is 40 g/m 2 with a roll width at the winder of 190 cm.
  • the nonwoven is fed into a Raschel machine (Kettenwirkmaschine Raschel Gauge: E9, Karl Mayer Textilmaschinenfabrik, DE-Obertshausen) as a roll material having a width of 190 cm.
  • a Raschel machine Karl Mayer Textilmaschinenfabrik, DE-Obertshausen
  • PET filament yarns consisting of 35 filaments, are incorporated into the nonwoven by a lateral offset of the needle bar and reinforce the nonwoven with a velvet closed binding.
  • a stitch length of 0.33 cm (3 stitches / cm) with a division of 4.5 needles / 25 mm is obtained. This corresponds to a quantity of 4 % filament yarn per square meter.
  • the filament yarn is processed under tension.
  • the velocity of the machine is 1,8 m / min, corresponding to 400 strokes per minute.
  • the nonwoven having a total width of 185 cm, is pulled off via heating rollers and wound up.
  • the total width of the resulting fiber-enforced nonwoven is 155 cm.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
EP22153194.0A 2021-01-29 2022-01-25 Elastic nonwoven fabric and method of making the same Pending EP4036296A1 (en)

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DE102021102168 2021-01-29
EP21157877 2021-02-18

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0303497A2 (en) 1987-08-14 1989-02-15 E.I. Du Pont De Nemours And Company Stitched nonwoven dust-cloth
EP0390579A1 (en) 1989-03-31 1990-10-03 E.I. Du Pont De Nemours And Company Stitchbonded nonwoven fabric
EP0695382A1 (en) 1993-04-22 1996-02-07 Du Pont THICK, STABLE NON-WOVEN
WO2004092476A2 (en) * 2003-03-31 2004-10-28 Xymid, L.L.C. Composite sheet for use as artificial leather
WO2005091836A2 (en) * 2004-03-02 2005-10-06 Swz, Llc Elastic stitched composite fabric using inextensible yarns
EP3375602A1 (de) 2017-03-17 2018-09-19 Carl Freudenberg KG Schallabsorbierendes textilkomposit
WO2019200294A1 (en) * 2018-04-13 2019-10-17 Amtex Innovations Llc Stitchbonded, washable nonwoven towels and method for making

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4704321A (en) * 1986-11-05 1987-11-03 E. I. Du Pont De Nemours And Company Stitched polyethylene plexifilamentary sheet
US6936327B2 (en) * 2003-07-01 2005-08-30 Dimitri Peter Zafiroglu Stitch-bonded and gathered composites
US20150104604A1 (en) * 2012-09-10 2015-04-16 Mmi-Ipco, Llc Insulated composite fabrics

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0303497A2 (en) 1987-08-14 1989-02-15 E.I. Du Pont De Nemours And Company Stitched nonwoven dust-cloth
EP0390579A1 (en) 1989-03-31 1990-10-03 E.I. Du Pont De Nemours And Company Stitchbonded nonwoven fabric
EP0695382A1 (en) 1993-04-22 1996-02-07 Du Pont THICK, STABLE NON-WOVEN
WO2004092476A2 (en) * 2003-03-31 2004-10-28 Xymid, L.L.C. Composite sheet for use as artificial leather
WO2005091836A2 (en) * 2004-03-02 2005-10-06 Swz, Llc Elastic stitched composite fabric using inextensible yarns
EP3375602A1 (de) 2017-03-17 2018-09-19 Carl Freudenberg KG Schallabsorbierendes textilkomposit
WO2019200294A1 (en) * 2018-04-13 2019-10-17 Amtex Innovations Llc Stitchbonded, washable nonwoven towels and method for making

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