KR102134596B1 - 변형가능한 직물의 안정화 방법 - Google Patents

변형가능한 직물의 안정화 방법 Download PDF

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Publication number
KR102134596B1
KR102134596B1 KR1020190034816A KR20190034816A KR102134596B1 KR 102134596 B1 KR102134596 B1 KR 102134596B1 KR 1020190034816 A KR1020190034816 A KR 1020190034816A KR 20190034816 A KR20190034816 A KR 20190034816A KR 102134596 B1 KR102134596 B1 KR 102134596B1
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South Korea
Prior art keywords
fabric
fibers
mold
nonwoven web
fiber
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KR1020190034816A
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English (en)
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KR20190113638A (ko
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카이클 케니스
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스펀팝 리미티드
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Publication of KR102134596B1 publication Critical patent/KR102134596B1/ko

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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/105—Coating or impregnating independently of the moulding or shaping step of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • 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
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

안정된 직물을 제조하는 방법이 제공되며, 이 방법은 1) 보강 섬유로 형성된 제 1직물을 제공하는 단계; 2) 상기 제 1직물의 적어도 일면에, 상기 보강 섬유보다 낮은 연화 온도를 갖는 섬유로 제조된 부직포 웹을 제공하여 구조물을 형성하는 단계; 3) 상기 부직포 웹의 연화 온도와 용융 온도 사이의 온도로 상기 구조물을 가열하는 단계; 및 4) 상기 구조물을 냉각시켜 안정된 2차원 직물을 제공하는 단계를 포함한다. 바람직한 실시예에서, 단계 2)의 구조물은 가열 단계 3) 전에 금형에 넣고, 단계 3)에 따라서 금형 내에서 상기 구조물을 가열하고, 단계 4)에 따라서 금형 내에서 상기 구조물을 냉각시켜, 3차원으로 성형 물품을 제공한다. 또한, 이들 방법에 의해 제조된 제품도 제공된다.

Description

변형가능한 직물의 안정화 방법{STABILIZING A DEFORMABLE FABRIC}
본 발명은 방탄 조끼 같은 산업 분야에서 통상적으로 사용하는 안정화된 직물지(textile fabrics)에 관한 것이다. 또한, 본 발명은 그의 제조 방법에 관한 것이다.
직물지의 안정화는 여러 해 동안 문제가 되어 왔다. 1942년 6월 11일에 허여된 영국 특허 545,770의 명세서에는 직물지의 치수를 안정화시키는 방법이 개시되어 있다. 이 방법은 방사 전에, 가열시 고유한 점착성을 갖는 열가소성 섬유 및 직물 섬유 중 적어도 1종과 함께 혼합하여 제조되는 잠재적 점착성 섬유를 함유한 직물지를 제공하는 단계를 포함한다. 가열시, 열가소성 섬유는 직물 내에서 직물 섬유에 거의 영구적으로 접착되어 치수 안정성을 제공한다.
1976년 1월 7일에 허여된 영국 특허 1,420,517의 명세서에는 직조된 직물 구조를 안정화시키는 방법이 개시되어 있다. 이 방법은 상대적으로 낮은 연화 온도를 갖는 성분을 지닌 다성분 필름으로 형성된 테이프를 제공하는 단계를 포함한다. 이러한 테이프는 직물 구조를 안정화시키기 전에 이러한 직물 구조로 직조된다. 직물 구조의 안정화는, 낮은 연화 온도를 갖는 성분의 연화 온도와 용융 온도 사이의 온도까지 직물 구조를 가열하고, 그로 인해 상기 성분이 직물 구조에 결합되어 치수 안정성을 제공함으로써 달성된다.
1997년 11월 25일에 허여된 미국 특허 5,691,030에는 이러한 직물을 함유한 안정화된 직물 및 보강된 제품을 제조하는 방법이 개시되어 있다. 결합된 직물은 필라멘트들의 교차점에서 서로 결합된 코어-시스(core-sheath) 유형의 필라멘트 메시를 포함하도록 규정되어 있다. 보강을 제공할 수 있는 하나의 방법은 유리, 아라미드 또는 탄소 같은 원사(yarn) 둘레에 주요 보강사보다 낮은 융점을 갖는 또 다른 원사를 방사, 코어텍스쳐, 엔벨로프 또는 트위스트하고, 열 및 압력을 가해 저온융착사(lower melting yarn)와 보강사(reinforcement yarn)를 결합시킴으로써, 복합체를 제조하는 것이다.
성형 물품의 제조를 위해 설계된 안정된 직물을 제조하는 방법이 제공되며, 이 방법은 1) 보강 섬유로 형성된 제 1직물을 제공하는 단계; 2) 상기 제 1직물의 적어도 일면에, 상기 보강 섬유보다 낮은 연화 온도를 갖는 섬유로 제조된 부직포 웹(nonwoven web)을 제공하여 구조물을 형성하는 단계; 3) 상기 부직포 웹의 연화 온도와 용융 온도 사이의 온도로 상기 구조물을 가열하는 단계; 및 4) 상기 구조물을 냉각시켜 안정된 2차원 직물을 제공하는 단계를 포함한다. 바람직한 실시예에서, 단계 2)의 구조물은 가열 단계 3) 전에 금형에 넣고, 단계 3)에 따라서 금형 내에서 상기 구조물을 가열하고, 단계 4)에 따라서 금형 내에서 상기 구조물을 냉각시켜, 3차원 성형 물품을 제공한다. 또한, 이들 방법에 의해 제조된 제품도 제공된다. 대안적으로, 부직포 웹은 보강 섬유질 직물의 표면 상에 직접 형성될 수 있다.
도 1은 일면이 Spunfab Polyolefin PO4208 부직포 웹으로 코팅된 A&P TX 탄소 편조 섬유 평탄 섬유질 기재(carbon braid fiber flat fibrous substrate)의 사진이다.
도 2는 일면이 Spunfab Polyamide PA1203 부직포 웹으로 코팅된 A&P TX 탄소 섬유 편조 평탄 섬유질 기재의 사진이다.
도 3은 일면이 Spunfab Polyolefin PO4208 부직포 웹으로 코팅된 A&P 아라미드 편조 평탄 섬유질 기재의 사진이다.
도 4는 일면이 Spunfab Polyamide PA203 부직포 웹으로 코팅된 A&P 아라미드 평탄 섬유질 기재의 사진이다.
도 1 내지 도 4에 도시된 기재의 제조는 하기 실시예 1에 설명되어 있다.
세라믹, 폴리-알파 아라미드 또는 탄소 섬유 등의 섬유로 형성된 고 탄성률 직물로 3차원 형상을 성형하는 것은 특히 어렵다. 일반적으로, 특히 직물이 능직(twill) 또는 편조된(braided) 섬유 소재로 제조된 경우, 직물에 큰 간극을 갖는 왜곡된 소재가 만들어진다. 부직포 웹으로 고 탄성률 직물을 안정화시킬 경우, 직물이 그의 무결성을 잃지 않고 변형될 수 있게 함으로써, 보다 양호한 취급을 위해, 고 탄성률 보강 섬유질 직물을 상당히 안정화시키는데 도움을 준다.
이는 3차원 형상을 형성하거나, 비-3차원 형상에 비해 안정된 직물의 정렬상태를 유지하는 능력을 제공한다. 또한, 이는 탄성 부직포 웹을 사용하여 안정된 ±45° 직물의 제조를 가능케 한다. 부직포 웹의 안정화 없이, 3차원 형상 재료가 기계 방향 또는 횡 방향으로 응력을 받거나 잡아당겨지는 경우, 재료는 거의 그대로 유지되면서, 그 방향으로 종종 왜곡된다. 현재, 안정되지 않은 ±45° 편조 생산품은 전형적으로 폭과 안정성을 유지하기 위해 캐리어와 함께 제공된다.
부직포 웹은 보강 섬유의 연화 온도보다 낮은 연화 온도를 갖는 열가소성 섬유로 형성된다. 열가소성 섬유는, 바람직하게는 폴리아미드 또는 폴리올레핀, 예컨대 폴리에틸렌 또는 폴리프로필렌이며, 성형 공정을 용이하게 할 수 있는 탄성 섬유일 수 있다. 기타 바람직한 열가소성 섬유로는: 코-폴리올레핀(co-polyolefins), 폴리우레탄, 코-폴리에스테르, Pebax® 등의 폴리에테르 블록 아미드, Hytrel® 등의 폴리에스테르 엘라스토머, 스티렌-에틸렌-부틸렌-스티렌 중합체, 스티렌-부타디엔-스티렌 중합체, 폴리에테르케톤케톤 중합체, 폴리페닐렌 설파이드 중합체 및 폴리에테르 에테르 케톤 중합체가 있다.
보강 섬유로는, 바람직하게는 탄소 섬유, 세라믹 섬유, 폴리 알파-아라미드 섬유, Lycra® 등의 탄성 폴리우레탄 섬유, 폴리에스테르 섬유, 나일론 등의 폴리아미드 섬유, 폴리프로필렌, 초고 분자량 폴리에틸렌, Vectran® 등의 용융 방사 액정중합체(liquid crystal polymer) 섬유 및 Kuralon® 등의 폴리비닐 알콜 섬유가 있다. 보강 섬유질 직물이 일면에 부직포 웹을 갖는 관형 편조 Lycra 섬유인 경우, 본 발명의 방법은 스포츠 용품을 제조하는 데에도 사용할 수 있다. 이 제품은 암형(female form)으로 성형된 다음, 스포츠웨어나 패션 직물에 사용할 수 있다. 부직포 웹은 보강 섬유질 직물의 표면 상에 직접 형성될 수 있다.
실시예 1
A&P 아라미드 편조 섬유 및 A&P TX-45 편조 탄소 섬유로 만든 약 3 제곱야드(square yard)의 기재에서, 일면을 Spunfab 코-폴리아미드 PA1203 (6g/㎡) 또는 Spunfab 폴리올레핀 PO4208 (6g/㎡)의 부직포 웹으로 코팅하였다. 코팅된 아라미드 기재를 4인치Х4인치 크기의 사각형으로 절단하였다. 코팅된 탄소 섬유 기재는 4.5인치 직경의 원으로 절단하였다. 이들 기재는 각각, 직사각형 트레이 상에 올려 놓고 약 280℉로 예열된 오븐에 30-40초 동안 두었다.
실시예 2
가열 단계 전에, 실시예 1의 기재 각각을 약 1.5인치의 반경을 갖는 스테인레스 스틸 반구형의 알루미늄 금형에 넣은 다음, 약 300℉로 예열된 오븐에 30-40초 동안 두었다. 가열된 직물을 함유한 금형을 4온스(oz)의 압력 하에서 약 160℉로 냉각되도록 한 다음, 금형을 열고서 안정화된 직물을 꺼냈다. 안정화된 직물의 3차원 형상이 유지되었고, 직물의 치수도 거의 유지되었다.
실시예 3
가열 단계 후에, 실시예 1의 기재 각각을 약 1.5인치의 반경을 갖는 반구형의 스테인리스 스틸 금형에 넣었다. 미리 가열된 기재를 함유한 금형을 300℉로 유지되는 오븐 내의 금속 트레이 위에 추가로 10초 동안 두었다. 금형을 오븐에서 꺼내 대기압으로 냉각되도록 했다. 성형된 구조물을 금형에서 꺼냈고, 금형의 형상이 유지되었다.
이 방법은 특히, 세라믹, 카본 또는 듀퐁(Dupont)사에서 입수 가능한 KEVLAR® 폴리 알파-아라미드 섬유 등의 편조된 고 탄성률 원사로 형성된 성형 물품에 적용 가능하다. 이러한 안정화된 직물은 3차원 형태 또는 2차원 형태의 방탄 조끼에 사용할 수 있다. 탄소 섬유를 이용하는 경우, 3차원 성형 물품의 용도는 자동차 변속기 하우징, 자동차 시트백 패널 및 여성 가슴 지지체 및 스포츠웨어 등의 기타 성형 물품에서 찾아 볼 수 있다.
안정화될 직물의 표면에 부직포 웹을 도포하거나 초기에 형성하는 경우, 탄성 또는 비탄성 부직포 웹은 거의 평탄한 안정화된 재료를 제조하는데 사용할 수 있다.
이어서, 평탄한 물질을 부직포 웹의 연화 온도와 용융 온도 사이의 온도로 가열한 다음, 금형에 넣어 성형 물품을 형성할 수 있다. 안정화될 직물의 표면에 위치된 부직포 웹은 탄성 또는 비탄성, 연속 또는 불연속, 단일 또는 다층 직물일 수 있다.

Claims (14)

  1. 삭제
  2. 삭제
  3. 삭제
  4. 삭제
  5. 삭제
  6. 삭제
  7. 안정된 3차원 직물을 제조하는 방법에 있어서,
    1) 편조된(braided) 보강 섬유로 형성된 제 1직물을 제공하는 단계;
    2) 상기 제 1직물의 적어도 일면에, 상기 보강 섬유보다 낮은 연화점을 갖는 열가소성 섬유로 제조된 하나 이상의 부직포 웹을 제공하여 구조물을 형성하는 단계;
    3) 단계 2)의 상기 구조물을 금형에 넣는 단계;
    4) 상기 부직포 웹의 연화 온도와 용융 온도 사이의 온도로 상기 금형 내의 상기 구조물을 가열하는 단계;
    5) 상기 금형 내에서 상기 구조물을 상기 연화 온도 아래까지 냉각시키는 단계; 및
    6) 상기 금형으로부터 상기 구조물을 꺼내 안정된 3차원 직물을 제공하는 단계를 포함하는 방법.
  8. 삭제
  9. 제 7 항에 있어서, 열가소성 섬유는 폴리아미드 또는 코-폴리아미드인 방법.
  10. 제 7 항에 있어서, 보강 섬유는 탄소 섬유, 세라믹 섬유 및 폴리 알파-아라미드 섬유로 이루어진 군으로부터 선택되는 방법.
  11. 제 7 항에 있어서, 열가소성 섬유는 폴리올레핀 또는 코-폴리올레핀, 폴리우레탄, 폴리에스테르 또는 코-폴리에스테르인 방법.
  12. 삭제
  13. 삭제
  14. 제 7 항의 방법에 따라 제조된 제품.
KR1020190034816A 2018-03-28 2019-03-27 변형가능한 직물의 안정화 방법 KR102134596B1 (ko)

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DK3546166T3 (da) 2021-07-26
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KR20190113638A (ko) 2019-10-08
PL3546166T3 (pl) 2021-12-13
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LT3546166T (lt) 2021-09-27

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