GB1590827A - Sheet materials and themanufacture thereof - Google Patents

Sheet materials and themanufacture thereof Download PDF

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Publication number
GB1590827A
GB1590827A GB40351/76A GB4035176A GB1590827A GB 1590827 A GB1590827 A GB 1590827A GB 40351/76 A GB40351/76 A GB 40351/76A GB 4035176 A GB4035176 A GB 4035176A GB 1590827 A GB1590827 A GB 1590827A
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GB
United Kingdom
Prior art keywords
web
sheet
fibre
thermoplastics
fibres
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.)
Expired
Application number
GB40351/76A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Noxet UK Ltd
Original Assignee
British United Shoe Machinery Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by British United Shoe Machinery Ltd filed Critical British United Shoe Machinery Ltd
Priority to GB40351/76A priority Critical patent/GB1590827A/en
Publication of GB1590827A publication Critical patent/GB1590827A/en
Expired legal-status Critical Current

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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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • D04H1/42—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
    • D04H1/4274—Rags; Fabric scraps
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H1/498—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 entanglement of layered 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
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered 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
    • D04H13/00—Other non-woven fabrics
    • 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
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)

Description

(54) IMPROVEMENTS IN OR RELATING TO SHEET MATERIALS AND THE MANUFACTURE THEREOF (71) We, THE BRITISH UNITED SHOE MACHINERY COMPANY LIMITED, a British Company of Union Works, Belgrave Road, Leicester, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following state ment:- This invention is concerned with improvements in or relating to sheet materials and the manufacture thereof and is especially concerned with sheet materials suitable for use in the manufacture of shoe insoles.
In the manufacture of sheet materials comprising fibre webs it is sometimes a requirement that the properties of the sheet material on one face differ from those at the other face. For example, it is known to manufacture shoe insoles comprising a non-woven bonded fibre fabric web and for cost reasons igt is desirable that the fibres of the web should be scrap textile fibres; however, shoe insoles including bonded fibre fabric webs of scrap fibres are unsuitable for use in shoes in which no stuck-in sock is used because the scrap fibres are of unsightly appearance.
The invention provides, as one of its several features, a process for manufacturing sheet material comprising forming an assembly consisting of a first fibre web and a thermoplastics sheet in surface contact therewith, needle punching the assembly so that fibres of the web are punched through the sheet whereby to laminate the web to the thermoplastics sheet, assembling the laminate consisting of the web and thermoplastics sheet with a second fibre web the thermoplastics sheet being in surface contact with the second web and rendering the thermoplastics sheet adhesive whereby to bond together the laminate and the second fibrous web, without subjecting the laminate and the second fibrous web to needle punch ing after they håve been assembled.
The invention also provides, as another of its several features, sheet material comprising a first fibre web needle-punched to a thermoplastics sheet, and a second fibre web adhesive bonded to the first web by the thermoplastics sheet without needle punching the second fibrous web to the thermoplastics sheet.
The invention further provides, as yet another of its several features, a shoe insole comprising sheet material as set out in the last preceding paragraph.
Preferably, in carrying out a process in accordance with the invention, at least one of the fibre webs is, and more preferably both of the fibre webs are, non-woven fibre webs.
Preferably, in carrying out a process in accordance with the invention, the thermoplastics sheet is rendered adhesive by applying heat, through one or both of the fibre webs, sufficient to soften the thermoplastics sheet to a tacky condition. The heat may be supplied by any convenient means, for example, hot air or by contact of one or both webs with a hot surface. Suitably, in order to ensure good adhesion, pressure is applied. Conveniently both heat and pressure are applied simultaneously, for example by passing the laminate assembled with the second fibre web round a heated drum against which the web may be pressed for example by a tensioned belt, by a series of rollers or by a combination of a belt with one or more rollers.
The thermoplastics sheet is selected so that it may be rendered adhesive without damaging the fibres of either of the fibre webs. The thermoplastics sheet is selected to be of adequate strength to support thé first web and to be sufficiently adhesive to provide an adequate bond for the purposes for which the sheet material comes to be used. Where flexibility of the manufactured sheet material is of importance it is important to select thermoplastics sheet which has acceptable stiffness properties. Where the sheet material is to be suitable for use in the manufacture of shoe insoles the thermoplastics sheet is conveniently polyethylene between 0.05 mm. and 0.125 mm.
thick weighing between 20 and 50 g/sq.
metre; the heavier weights of sheet may be expected to give a stronger bond between the laminate and the second web.
In carrying out a process in accordance with the invention the fibre webs are selected according to the properties which are desired in the finished sheet material. For example, in carrying out a process in accordance with the invention for manufacturing sheet material suitable for use in the manufacture of shoe insoles the first fibre web is preferably a light weight nonwoven fibre web, preferably having a weight of between 50 and 150 grams per square metre and more preferably of about 65 grams per square metre, the fibres of the first non-woven web being virgin fibres, for example a mixture of rayon, nylon and polyester virgin fibres, or polyester virgin fibres alone. Where the sheet material is to be suitable for use in making shoe insoles the first web is conveniently needle-punched to the thermoplastics sheet using needles of about 32 gauge and a needle-punch density of preferably not more than 100 and more preferably about 50 per square centimetre.
The gauge of needle used is selected according to the properties desired in the sheet material, as is the punch density. Where it is desired that the sheet material should be water absorbent to some extent it is important to ensure that the perforation area per unit area of sheet material is sufficient to permit adequate transmission of water.
It is, however, also important to ensure that the degree of needle-punching does not carry so many fibres through the sheet as to deleteriously affect the bond between the laminate and second web, while yet the first web is adequately held onto the thermoplastics sheet. The second fibre web in a process in accordance with the invention for manufacturing sheet material suitable for use in the manufacture of shoe insoles is preferably a heavily needlepunched non-woven web of much heavier weight per unit area than the first web, preferably between 300 and 700g./square metre conveniently about 455 grams per square metre; preferably the needle punch density lies between 300 and 1000 punches per square centimetre, more preferably about 500 punches. The fibres selected for the second web may be any scrap fibres which are suitable for use in shoe insoles of nonwoven bonded fibre fabrics, for example a mixture of scrap nylon, polyester and acrylic fibres has been found suitable; preferably the second web contains little or no rayon fibre. Conveniently where the sheet material is to be suitable for use as a shoe insole the second web comprises at least 13 by weight nylon fibres.
In further carrying out a process in accordance with the invention the laminate with the second non-woven web bonded thereto by the thermoplastics sheet may be impregnated with a bonding agent of a known type, for example aqueous dispersions of styrene butadiene copolymer or butadiene acrylonitrile copolymer may be used as impregnating agents. Suitably, where a bonding agent is incorporated in carrying out a process for manufacturing sheet material in accordance with the invention it is selected to achieve properties desired in the sheet material, for example in manufacturing sheet material suitable for use in shoe insoles a bonding agent is selected which results in a sheet material having a surface with adequate abrasion resistance, rigidity, lamination strength, and tensile strength.
The amount of bonding agent incorporated is likewise chosen according to the properties of the material which it is desired to achieve, about 1 part by dry weight of bonding agent to 1 part by weight of the fibre webs bonded by the thermoplastics sheet may suitably be used for making sheet materials suitable for use in the manufacture of shoe insoles.
If desired, in carrying out process in accordance with the invention, the exposed surface of at least one of the first or second non-woven fibre webs may be coated with a suitable coating composition to further improve surface properties.
In carrying out a process in accordance with the invention, where the sheet material is to be of a specific thickness it may be necessary to finally calender the material to achieve the desired thickness. However, such calandering tends to soften the material too much and is preferably avoided by controlling the process carefully, for example the pressure applied during the laminating process may conveniently be adjusted to control the final sheet thickness.
There now follows a detailed description of a process for manufacturing sheet material, namely sheet material suitable for use in the manufacture of shoe insoles. It will be realised that this process has been selected for description to illustrate the invention by way of example and not of limitation of the invention.
In carrying out this illustrative process a first non-woven textile fibre web comprising 60 parts by weight viscose rayon fibres, 30 parts by weight nylon fibres and 10 parts by weight polyester fibres was made in known manner on oonventional equipment for forming non-woven fibre webs, namely a carding plant; however, other conventional equipment for forming non-woven webs, e.g. an air layer, could be used if desired.
The first non-woven fibre web has a weight of about 65 grams per square metre.
Next, in carrying out the illustrative process, the first non-woven fibre web was fed into the surface contact with á thermoplastics sheet and the first non-woven web with the thermoplastics sheet in contact therewith was needle-punched in a com mercially available needle loom. The needles used were 32 gauge and the punch density was about 50 punches per square centimentre. The thermoplastics sheet was an industrial grade low density polyethyl ene sheet having a melting point of about 1150C and the sheet had a weight of about 20 grams per square metre. The degree of needling was such that the first non-woven fibre web remained on that side of the thermoplastics sheet to which it was applied and only a few fibres were punched through the thermoplastics sheet, sufficient merely to laminate the first non-woven fibre web to the thermoplastics sheet. The laminate consisting of the first non-woven fibre web and the thermplastics sheet was then rolled up.
Next, in carrying out the illustrative process a second non-woven textile fibre web was made of scrap fibres using carding apparatus. The textile fibres used comprised nylon waste (over i by weight), polyester fibres, and acrylic fibres with small amounts of other fibres. The carded fibres were then passed through a needle loom and needle punched using 43 gauge needles and a punch density of 500 punches per square centimetre, thus to form the second nonwoven textile fibre web.
In further carrying out the ilustrative process, the laminate oonsisting of the first non-woven fibre web and the thermoplastics sheet was assembled with the second nonwoven fibre web, the laminate and the second non-woven fibre web being fed from rolls, with the thermoplastics sheet in surface contact with the second web, into engagement with a steam heated drum. The first non-woven fibre web was in engagement with the surface of the drum. The surface of the drum was provided by a smooth release coating carried on a metal undersurface. The temperature of the surface of the drum was about 1400C. The laminate and second web were held in contact with the drum by a tensioned belt (applying a pressure of about 3.5 libs. per square inch) to ensure good thermal contact between the drum surface and the first web and to consolidate the fibre webs to some extent. As the laminate and second web were fed into engagement with the drum surface they passed through a nip between a roll, acting through the belt, and the drum surface, the roll applying a load of about 8 lbs. per inch width, across the material; the pressure applied by the roll was sufficient to ensure that the thermoplastics sheet was firmly pressed against the second web. The laminate and second web then progressed round the drum sur face and heat from the drum softened the thermoplastics sheet. The laminate and the second web, after the thermoplastics sheet had reached an adhesive condition, (having been in contact with the drum for about 30 seconds) passed through a nip formed between the drum surface and a second roll which exerted a load of about 74 lbs. per inch width, thus to bond together the laminate with the second fibrous web.
The laminate with the second fibrous web bonded thereto had a total weight of about 540 grams per square metre.
In further carrying out the illustrative process the laminate with the second fibre web bonded thereto by the thermoplastics sheet was passed through a bath of a suitable impregnant and excess impregnant was removed by passage of the material through stripper rolls. The impregnated material was dried by passage through an oven in which were mounted radiant heaters and by passage round heated drums (contact of the surface of the material with the surface of the drum imparted a smooth surface finish to the material). The final dried weight of the sheet material, which was itself illustrative of the invention in its sheet material aspects, was about 1080 grams per square metre and the material was about 2.3 mm. thick.
By avoiding needling through the whole thickness of the sheet material in the course of its manufacture, the possibility that some of the scrap fibres from the second web might be pulled through the material, to the surface of the first web, thus spoiling the appearance of the surface, was eliminated.
The illustrative sheet material was satisfactory in both performance and appearance for use as a shoe insole in the manufacture of a shoe having no sock-lining.
The impregnant composition used in carrying out the illustrative process comprised a rubbery, plasticised styrene copolymer aqueous dispersion having a solids content of about 50% by weight, and an amount of a compatable pigment. The styrene copolymer comprised about 85to by weight styrene and 15% by weight butadiene with a trace of a third monomer.
In carrying out a process in accordance with the invention otherwise similar to the illustrative process, a surface coating may be applied to the first web, for example to give improved abrasion resistance where this is necessary. This modified process in accordance with the invention was identical to the illustrative process except that, immediately after the material had been impregnated with the binding agent and had passed the radiant heaters (which act to precipitate the binding agent and to dry the material to some extent) a coating was applied. The material passed round a roll against which a blade was laid, the coating material being supplied to the gap between the blade and the roll thus to apply a coating to the material the thickness of which was determined by the spacing of the blade from the roll. In the modified version of the illustrative process in making a shoe insole the coating applied was very thin and the coating material was an aqueous dispersion comprising particles of a vinyl chloride copolymer and particles of a carboxylated high nitrile content rubber containing zinc oxide as a curing agent.
The vinyl chloride copolymer and the carboxylated rubber were present at about equal parts by weight of the dried coating.
Subsequent to being coated, the coated face of the material was heated by radiant heaters to precipatate the coating and to dry some of the moisture from the coating.
The material was then passed round steam heated drums, being pressed against the first of the drums by a roller to give a smooth surface finish, and to cure and fully dry the coated material. The material made by this modified version of the process was also illustrative of the invention in its material aspects.
WHAT WE CLAIM IS: 1. A process for manufacturing sheet material comprising forming an assembly consisting of a first fibre web and a thermoplastics sheet in surface contact therewith, needle punching the assembly so that fibres of the web are punched through the sheet whereby to laminate the web to the thermoplastics sheet, assembling the laminate consisting of the web and thermoplastics sheet with a second fibre web the thermoplastics sheet being in surface contact with the second web and rendering the thermoplastics sheet adhesive whereby to bond together the laminate and the second fibrous web, without subjecting the laminate and the second fibrous web to needle punching after they have been assembled.
2. A process according to claim 1 wherein the thermoplastics sheet is rendered adhesive by applying heat.
3. A process according to claim 2 wherein the heat is supplied by contact of one of the fibre webs with a hot surface.
4. A process according to any one of the preceding claims wherein the bonding together of the laminate and the second fibrous web is facilitated by application of pressure.
5. A process according to any one of the preceding claims wherein the thermoplastics sheet is between 0.05 mm and 0.125 m thick and weighs between 20 and 50 g/square metre.
6. A process according to any one of the preceding claims wherein at least one of the fibre webs is a non-woven fibre web.
7. A process according to claim 6 wherein the first fibre web is a non-woven fibre web having a weight of not more than 100 grams per square metre.
8. A process according to claim 7 wherein the needle-punch density at which the first fibre web is needled to the thermoplastics sheet is not more than 100 punches per square centimentre.
9. A process according to any one of claims 6 to 8 wherein the second fibre web is a non-woven fibre web having a weight of between 300 and 700 grams per square metre.
10. A process according to claim 9 wherein the second fibre web is needlepunched to a punch density of between 300 and 1000 punches per square centimetre.
11. A process according to either one of claims 9 and 10 wherein the fibres of the second web comprises at least 1 by weight nylon fibres.
12. A process according to any one of the preceding claims wherein the laminate having the second fibre web bonded thereto is impregnated with a bonding agent.
13. A process according to claim 12 wherein the bonding agent comprises styrene butadiene copolymer.
14. A process according to any one of the preceding claims wherein after bonding of the laminate to the second fibre web the exposed surface of at least one of the fibre webs is coated with a coating composition.
15. A process for manufacturing sheet material substantially as hereinbefore described.
16. Sheet material made by a process according to any one of the preceding

Claims (1)

  1. claims.
    17. Sheet material comprising a first fibre web needle-punched to a thermoplastics sheet, and a second fibre web adhesively bonded to the first web by the thermoplastics sheet without needle punching the second fibrous web to the thermoplastics sheet.
    18. Material according to claim 17 wherein at least one of the webs is a nonwoven fibre web.
    19. Material according to claim 18 wherein the first fibre web is a non-woven web having a weight of not more than 100 grams per square metre.
    20. Material according to either one of claims 18 and 19 wherein the second fibre web is a non-woven web having a weight of between 300 and 700 grams per square metre.
    21. Material according to any one of claims 17 to 20 impregnated with a bonding agent.
    22. Material according to any one of claims 17 to 21 comprising a coating on the exposed surface of at least one of the fibre webs.
    23. A shoe insole comprising sheet material according to any one of claims 16 to 22.
GB40351/76A 1977-09-28 1977-09-28 Sheet materials and themanufacture thereof Expired GB1590827A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB40351/76A GB1590827A (en) 1977-09-28 1977-09-28 Sheet materials and themanufacture thereof

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Application Number Priority Date Filing Date Title
GB40351/76A GB1590827A (en) 1977-09-28 1977-09-28 Sheet materials and themanufacture thereof

Publications (1)

Publication Number Publication Date
GB1590827A true GB1590827A (en) 1981-06-10

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GB40351/76A Expired GB1590827A (en) 1977-09-28 1977-09-28 Sheet materials and themanufacture thereof

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2567547A1 (en) * 1984-04-10 1986-01-17 Texon Inc COMPOSITE MATERIALS FOR PREMIERE AND METHODS OF MAKING THESE COMPOSITE MATERIALS AND OTHER SHOE MATERIALS
US5490892A (en) * 1993-02-17 1996-02-13 Societe Europeenne De Propulsion Method of fabricating a composite material part, in particular a sandwich panel, from a plurality of assembled-together preforms
EP0730059A2 (en) * 1995-03-03 1996-09-04 Renzo Stellini Method for improving fabrics made of natural or synthetic fibers, and textile material obtained with the method
WO2000053416A1 (en) * 1999-03-10 2000-09-14 Texon Uk Limited Laminar materials suitable for use in the manufacture of shoes, method of making same and shoe stiffener materials including said laminar materials

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2567547A1 (en) * 1984-04-10 1986-01-17 Texon Inc COMPOSITE MATERIALS FOR PREMIERE AND METHODS OF MAKING THESE COMPOSITE MATERIALS AND OTHER SHOE MATERIALS
US5490892A (en) * 1993-02-17 1996-02-13 Societe Europeenne De Propulsion Method of fabricating a composite material part, in particular a sandwich panel, from a plurality of assembled-together preforms
EP0730059A2 (en) * 1995-03-03 1996-09-04 Renzo Stellini Method for improving fabrics made of natural or synthetic fibers, and textile material obtained with the method
EP0730059A3 (en) * 1995-03-03 1998-05-13 Renzo Stellini Method for improving fabrics made of natural or synthetic fibers, and textile material obtained with the method
WO2000053416A1 (en) * 1999-03-10 2000-09-14 Texon Uk Limited Laminar materials suitable for use in the manufacture of shoes, method of making same and shoe stiffener materials including said laminar materials

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