KR19990037961A - New Synthetic Bet - Google Patents

Abstract

The present invention relates to a polyester composite fiber for use in improved apparel and other applications, made from low dpf (denier per filament) polyester fibers and adhesive fibers sprayed with soft resin by adhesion using an oven. It's about bats. The present invention is characterized by having softness and drape, good insulation, improved durability against washing such as low levels of oil leakage or exudation through the shell fabric, washing / drying or dry cleaning, Bonded bets are provided that have improved structural integrity that allows them to hang freely without the need for quilting.

Description

New Synthetic Bet

The present invention relates to bonded polyester synthetic fiber batts, sometimes referred to as batts, improved batters with particularly desirable appearance and quality, and articles comprising such improved batts.

In U.S. Pat.Nos. 5,225,242 and WO 93/11292, which are incorporated herein by reference, the present inventors disclose that an adhesive having an adhesive material having a melting point of about 70 to 96% by weight of polyester synthetic cotton and lower than the softening point of the polyester synthetic cotton Forming an intimately blended blend of about 4 to about 30% by weight of a bifibrous fiber, preferably a binary adhesive fiber, from which the continuous batt has a top and bottom face, and wherein the bat is one or more spray zones Spray both sides of the bat with a resin (wherein the total amount of resin is from about 10 to about 30% of the weight of the sprayed bat, including the resin, and after curing, the resin has a glass transition temperature of about 0 ° C. or less). (Tg), the sprayed bat is heated in an oven to cure the resin and soften the adhesive material, and then the heated bat is hot-pressed. Rolling to bring the resin and fibers in close contact with the top and bottom surfaces of the bat (where hot-rolling is preferably carried out using heated rolls of calender or S-wrap type) and rolled bat Provided is a method of making a bonded bat, comprising cooling the bonded bat, by which a bonded bat is produced having improved appearance and function.

The weight of the fibers in the bat (i.e., the blend of polyester composite and adhesive fibers) is called the "base weight" of the bat, i.e. the weight before the sealing resin is sprayed.

Surprisingly, however, in accordance with the present invention, when assisting to seal one or both sides of the bat using a low denier composite surface (variably referred to as subdenier or microfiber), proper sealing is obtained. It has been found that a high temperature rolling process is not necessary. Thus, there is provided a novel bonded batt having a top and bottom face, wherein the bat comprises from about 75 to about 96% of a polyester composite fiber of up to about 1 denier per filament, and supplementally based on the basis weight of the bat Fully bonded with about 4 to 25% low melting point adhesive material and having at least 4 wash resistance (WD as defined below) and flexural strength of about 40 cN / cm 2 or less (B as defined below), the bat one or more than about 0 to about 0.02 with respect to the surface of the batt with a resin having a glass transition temperature (Tg) of less than about ℃ the surface of 0.35oz / yd ^2, preferably about 0.1 to about 0.25oz / yd ² Sealed in positive amounts, the sealing grade of this face (SR as defined below) is at least 4. Preferably each of said surfaces is sealed as above.

In metric units such as dtex and denier, one dtex is equal to 0.9 denier per filament.

Thus, the present invention first prepares a homogeneous blend of polyester synthetic cotton (75-96% by weight of the blend) and suitable adhesive fibers (4-25% by weight of the blend), thereby producing a synthetic cotton batt for use in the high-grade streams. to provide.

This blend is converted to a web on a car or garnet and then layered or overlapped to form a batt, and its top face (and preferably continuously on its bottom face), for example, by spraying Suitable latexes (eg, colloidal dispersions of acrylic polymers and / or copolymers in water, as described below) are applied. The sprayed batt is conveniently heated, for example, by passing through a heated oven to dry the coating, polymerize the polymer component to high molecular weight, and activate the adhesive fibers. This is done, for example, by passing the oven through three passages, where the two passages are applied to any surface, and then each of these coatings is subsequently dried and partially cured, with the last one passage remaining. And activate adhesive fibers for any hot-rolling process, where the bonded batt passes through or around a heated roll (S-wrap or calendering process) to soften the cured resin and By dispersing it completely and evenly among the fibers in the batt's surface to prevent leakage of the fiber through the batt's surface and, if desired, as desired in US Pat. No. 5,255,242, as desired by the bat. To have.

However, synthetic fiber surface is 0.2 to 1 denier per filament, and wherein the resin applied to the batt plane has a glass transition temperature of about 0 ℃, about ^{0.02oz / yd 2 (0.7g / ㎡} ) to about 0.35oz / yd ² (12g / M 2), especially when using dry synthetic cotton, no further treatment is required, such as treatment with hot rolls, to prevent fiber leakage. Hot roll treatment can be applied to ensure that the bat has the desired thickness and reduces the flexural strength.

Resins that may be used herein are variously defined by other manufacturers, such as "soft" or "medium" or "quite soft", characterized by having a secondary glass transition temperature (Tg) of about 0 ° C. or less. do.

They provide both ductility and drapeability to the bat while serving as a barrier to preventing fiber leakage from the bat, for example when used in apparel. The final batt may have a basis weight of 1.5 to 12 oz / yd ² (50 to 400 g / m 2) and a thickness of 0.07 to 0.20 in / oz / yd ² (0.05 to 0.15 g / m 2).

The bats of the present invention are also made from blends of polyester composite cotton and adhesive fibers, and the fibers in the face (s) are suitably sealed with a soft-shaped resin coating. The polyester synthetic cotton may be, for example, all smoothed as described herein, or a blend of smoothed and unsmooth fibres.

The synthetic cotton may be solid fibers, hollow fibers and blends of solid and hollow fibers, and have any type of fiber cross section, namely cross, trilobal, Y, dog bone, scalloped oval and other acyclic cross sections as well as annular Can be. The synthesizing plane is 0.2-10 denier (dpf) per filament, very usefully about 1.65 dpf, and accounts for about 70-96 weight percent of the blend. As mentioned, the fibers of the subdenier form good sealing force on the bonded bat face (s), and for this reason are more preferred for the face (s). Individual fibers are gathered by conventional means and typically exhibit 5 to 15 pleats per in and have a length of 3/4 to 3 inches.

The adhesive fibers are about 4 to 30 weight percent based on the batt, and may be in the form of seeds / core (s / c), cotton / cotton (s / s) or single component.

These can be obtained from (co) polyesters, polyolefins, polyolefins / polyesters, polyamides / polyamides and the like. Useful forms of adhesive fibers and their forms of action are described in "Nonwovens World", "March / April 1990, page 37. The initial dpf of suitable adhesive fibers in the blend is typically 2-15, Typically 4dpf Useful adhesive fibers include Scott, Palm, Francosky and Marcus, as well as the above-mentioned United States patents; Harris, et al. 4,732,809; U.S. Patent No. 4,789,592 to Taniguchi et al .; U.S. Patent No. 4,500,384 to Tomioka et al .; It will include fibers disclosed in patents known in the art and will operate within the oven temperatures disclosed herein Preferred adhesive fibers are commercially available "Melty 4080" (Unitika Co., Japan). ) And "ES" and "EA" Include Li olefin (Japanese jitsso Corporation (Chisso Corporation) product).

The cured resin coating on both sides of the bat is conveniently constructed from about 10 to 30% by weight, preferably from 12 to 25% by weight relative to 1.65 dpf (1.83 dtex), based on the weight of the final bonded bat. While there is a tendency to reduce wash resistance and sealing rate, higher amounts of resin tend to increase stiffness and decrease insulation efficiency.

When sealing only one side of the bat, only half of the resin needs to be applied. If low denier fibers (about 1 dpf or less) are used, less resin coating is needed to control fiber leakage. In addition, the amount of resin in the surface (s) does not need to vary depending on the basis weight of the batt, and for heavier bats, even smoothed synthetic fiber batt, the total resin addition amount may be as low as 3% by weight. For dry (non-smoothed) fibers as a whole, resins are less necessary than with smoothed synthetic fibers.

As already mentioned, suitable resins for coating have a Tg of about 0 ° C. or less. Useful resins include, for example, Rhoplex E-32 (Rom and Haas Co.), TR-934 (Rom and Haas Co.), x-4280J (Kanebo, Japan), BF Goodrich Co. Latex compositions (26146, 26171, 26322, 26083, 26092, 2671, 26120, 2679, 26796), Latex products from National Starch and Chemical Corporation (NACRYLIC X 4445, NACRYLIC X 788-6007, NACRYLIC X 4483, NACRYLIC X 4460) , NACRYLIC X 4260, NACRYLIC X 4425, NACRYLIC X 4465, NACRYLIC 4401, NACRYLIC X 78-3990, NACRYLIC X 78-3997, NACRYLIC X 78-3905, NACRYLIC X 4280, NACRYLIC 4441, NACRYLIC 78-6114, X-LINK 2873 , X-LINK 2849, X-LINK 78-6119, X-LINK 2893, X-LINK 2833, X-LINK 78-6004, X-LINK 2813, RESYN 2375, DUR-O-SET E-230, DUR-O -SET E-669, and other commercially available latexes that cure to resins with Tg values below 0 ° C. Some of these commercially available resins and their Tg values include, for example, Haika from BF Goodrich. It is listed in the 1989 pamphlet under the trademarks Binders, Saturants, Laminants of Acrylic Latex and National Starch and Chemical Corporation.

The manufacture of batts is generally disclosed and the web is prepared by blending the polyester composite and adhesive fibers and then carding or garnetting.

The web may be layered with other webs from a row of cards or garnets, or may laterally overlap and mix with the other webs to form an unbonded bet.

It is then sprayed with a latex composition on one or both sides of the bet and fed into an oven to cure the resin and adhere the adhesive fibers. The oven treatment may be carried out at 150 to 190 ° C. for 2 to 5 minutes and may conveniently be carried out in three passages of the bat as already mentioned.

The bonded batt is then passed through a hot roll (preferably two or more) (three or more rolls may be used) having a surface temperature of 150 to 250 ° C. or overlying the roll. The structure of the bet may be wrapped with an S letter to the roll to provide maximum contact with the roll.

Depending on the thickness of the final bet desired, the maximum contact with the roll may have a separation distance of 2 to 5 mm.

Optionally, the bonded bet may pass through a heated calender roll as described above.

In this process, only one roll may be heated, even if both sides of the bat are sealed as needed, and if the purpose is to seal both sides, the roll may be passed for a second time to heat the opposite side of the bat or The roll may be excessive. The contact time for the roll is 3 to 25 seconds.

This hot roll treatment softens and spreads the resin, completely and evenly distributing it on the batt surface to prevent fiber leakage and to provide a uniform surface free of lumps for safe and aesthetic performance in use. Bats represent base weights and thicknesses in the above ranges.

Bats of the present invention often exhibit the desired level of heat resistance or insulation, as reported as a CLO grade (see US Pat. No. 4,514,455 to Hwang).

Batt of the present invention is not required with about 0.36CLO / oz / yd ² CLO value or more indicates a preferably 0.48 CLO / oz / yd ² or more.

It is to be understood that the components and methods described herein are chosen to provide the bats of the present invention. Combinations that provide batts of the invention should be carefully selected. For example, the latex applied to the fibrous smoother and batt should be chosen to adhere sufficiently, so that the final batt may, for example, exhibit sufficient wash resistance.

Test procedure

The CLO rating is as described in the sulfur patent.

The wash resistance ("WD") of the present invention is evaluated by the procedure of ASTM D-4770-88. In the examples, the panels were 24 inches by 24 inches in size. Durability grades are reported as measured according to 8.6.1. The bat of the present invention exhibits a grade of at least 3 (8.5 ratio portion).

Fiber leakage or exudation through the shell fabric is measured as a sealing grade (“SR”) by the method described in US Pat. No. 4,869,771 to LeVan (after three wash cycles). If the sealing grade SR is 5, it is excellent, and if the sealing grade SR is 1, it is bad.

The bat of the present invention exhibits a sealing grade (SR) of at least 3 (after 3 wash cycles). In Table 2 (Example 3), the sealing grade values are reported more after 3 washes (3W) as well as after 1 wash (1W) and freshly washed after comparison with the initial values.

The ductility or drape of the bat of the present invention is determined according to the Federal Republic of Industry Standard 53362 Cantilever, which determines and sums the flexural strength ("B") of the bat in the machine and cross machine directions; The combined result is related to drape and ductility.

Bat samples are cut in the machine direction (MD) and cross machine direction (XD) with a length of 25 cm and a width of 2.5 cm. Weigh each test specimen and record its weight as "W".

The bent length ("LU") is then determined by sliding horizontally on the sample tomb platform until the front side of the bent sample is at an angle of 41 ° 30 ".

Then calculate as follows:

B = F ₁ (LU ÷ 2) ³

Where B is the flexural strength (cN / cm 2), LU is the bent length (cm), F ₁ is 9.8 (W ÷ L), W is the weight of the sample specimen (g), and L is the length of the sample specimen (Cm)

Bats of the present invention exhibit a flexural strength of 80 cN / cm 2 or less (“B” is the sum of the values determined for the MD and XD samples from the bat), with lower flexural strength being preferred.

The invention is further illustrated in the following examples in which all parts and proportions are by weight unless otherwise indicated and are only "BW" (base weight), i.e., only for the amount of polyester composite and adhesive fibers (i.e. seals). Calculate, except for resin added by spraying on the face to improve the ring.

Various bat samples were prepared and tested and the results are shown in the table. Each time the adhesive fiber was "Melty 4080" (4dpf), but different synthetic fiber was used.

Samples A, B, C, and D are commercially available polyester fibers consisting of 37.5% smoothed 1.65 dpf (surface treated with a silicon smoother), 37.5% dry 1.65 dpf (without silicone smoother), and 25% adhesive fibers Made from Blendy. The blend was processed in a cross-lapper device similar to the device described in Example 1 of conventional card and US Pat. No. 5,225,242. The resulting bets were fed through a triple pass oven maintained at about 165 ° C. The total amount of resin added to each side of the batting (except A) is based on "BW" (the basis weight of the fibers in the batt at this stage is about 4.5 oz / yd ² (150 g / m 2)) The same amount of soft resin (glass transition temperature (Tg) is −10 ° C.) was sprayed as follows. After the resin was sprayed on one side of the bet, the first passage was entered, and the resin was sprayed on the other side, and the second passage was entered. It is important to expose the entire bet for a suitable time at a high temperature sufficient to ensure complete curing of the resin and fixation of the adhesive fibers (generally one minute after reaching 165 ° C.).

The bets were then calendered in a separate process that acts to seal the surface and reduce the loft.

In the sealing grades of the table, under the above conditions, even with 8% resin (Sample B), the calendaring effect does not improve the sealing of 1.65dpf fibers after one wash, and wash once with 15% resin (Sample C). The sealing improved afterwards, but after 3 rounds it was still insufficient. With 25% resin under these conditions, the sealing grade on the sample D surface was satisfactory (after three washes).

The batting was also wrapped in a yarn number of 104 × 84 yarns and tested for fiber leakage at a Frazier air penetration rating of 13.2 cu ft / min at a pressure of 0.5 in of water.

Samples E and F were the same except that they were tested with 102 × 84 yarn number fabric and 48 Frazier grade fabrics, respectively. As tested on 0.7dpf bets or more permeable fabrics than Samples A through D, the results in Samples E and F (1.65dpf) are included among the data of Samples A through D and G through Q in the table.

Resin-free, Sample E failed at new times due to the openness of the fabric but effectively mated after three washes to improve leak protection. The sealing grade of Sample F was initially 5 and provided a satisfactory sealing grade after three washes.

Samples G, H, I and J were prepared from a mixture of about 85 pounds of dry polyester fibers (0.7 dpf, 0.78 dtex, 1.5 inch cut, 12 cpi, without any specific smoothing post-treatment) and 15 pounds of adhesive fiber. .

The samples were resin-sprayed, calendered and tested for Samples E and F.

Samples K and L are similar about 55 pounds of 0.7dpf glossy fiber, 27 pounds of dry (non-smoothed) 0.7dpf fiber and 18 pounds of adhesive fiber, 27 pounds of dry (non-smoothed), post-treated with a silicone smoothing agent. ) Is made of a mixture of 0.7dpf fibers and 18 pounds of adhesive fibers. These samples are not calendared as indicated by ** in the table, but provide a good sealing grade.

Samples M, O, and P made from blends of the same kind as K and L, but with a higher basis weight, are calendered due to the lower (10% or less) resin addition and the use of low dpf fibers But it also shows a good sealing grade.

N is calendared unlike others. A comparison of these results shows that calendering is not necessary to improve the sealing grade (lower day fibers were used with softer resins).

Samples G through L were all tested for fiber leakage with fabrics at 48 prage.

Thus, in the table, samples G to I and K to Q are all in accordance with the present invention, while other samples are for control, some of which are not sprayed with any resin and some are filled with regular denier fibers, and their seals. The ring grade shows that it is not appropriate after washing.

[table]

* Denotes the total amount of resin sprayed on the batt (both sides), calculated as oz / yd ² (half of this amount each side).

** indicates no calendaring after oven curing.

Claims (3)

In a bonded batt having an upper and a lower surface, The batt comprises from about 75 to about 96% polyester sump cotton of up to about 1 denier per filament, based on the basis weight of the bat, and is fully adhered to about 4 to 25% low melting point adhesive material, Having a wash resistance (WD as defined herein) and a flexural strength of about 40 cN / cm 2 or less (B as defined herein), at least one of the faces of the batt having a glass transition temperature of about 0 ° C. or less ( Resin with Tg) and is sealed in an amount of about 0.02 to about 0.34 oz / yd ² relative to the face of the bat, wherein the face sealing grade (SR as defined herein) is 4 or greater. bat. The method of claim 1, The amount of resin is from about 0.1 to about 0.25 oz / yd ² bat. The method according to claim 1 or 2, Each of the upper and lower surfaces is sealed with the above-described amount of resin and has a sealing rating of 4 or more. bat.