MXPA97008589A - Composite sheet resistant to abras - Google Patents

Abstract

A composite sheet having a surface layer (17) of vertical hair-like fibers (10) impregnated with resins is provided which provides the sheet with unusually high resistance to abrasive wear. The surface layer (17) has a combination of characteristics that include an effective concentration of fibers and hairs of 0.1 to 0.5 g / cm.sup.-1, and a total density of at least 0.4 g / cm.sup.-one resin content of 25 to 90%. in weight and a hair parameter of at least 0.3 grams / cm 2, the hair-like fibers (10) contained within the surface layer (17) are derived from particular contracted woven fabrics or from fabrics (20) of sewn fabric of two contracted bars

Description

SHEET. COMPOSITE ABRASION RESISTANT BACKGROUND OF DJVENC-tNr AI Field of the Invention This invention relates to a composite sheet resistant to abrasion and to a process for manufacturing the sheet. More particularly, the invention relates to a composite sheet in which groups of hair-like fibers are immobilized by a resin in a position that is generally vertical with respect to the surface of the sheet.

Description < In the Previous Technique It is known to laminate various woven or non-woven fabrics to resin layers to form composite sheets designed for use in thermoforming processes and molding. For example, such composite sheets are described in Miyagawa et al., U.S. Patent 4,298,643, Zafiroglu, U.S. Patent 5,075,142, and in the publications for Japanese Patent Application 63-111050 and 63-162238. Moldable composite materials have been used in many applications. However, such REF: 25774 Compositions require improvements when they are designed for use in items that are subjected to strong abrasion, for example, in parts of athletic shoes, luggage surface layers, protective work clothes, heavy duty bags, etc. Fabrics with hairs and hair-like fabrics, such as velvets, velor, sponge fabric, carpets and fabrics with hairs and curl formation have a surface layer in which the fibers are generally vertical with respect to the surface of the fabric. In addition, Zafiroglu, US Patent 4,773,238 and 4,876,128, discloses certain sewn fabrics in which the fibrous layers are contracted by means of elastic threads to form groups of hair-like fibers. Generally, such fabrics are not described for incorporation of composite sheets impregnated with resin. However, Japanese Patent Laid-open Applications 64-85614 and 64-85615 disclose a floor mat which includes fabric with plush hair to which a rubber resin has been added. The plush hairs have a hair height of 8 mm and a hair fiber concentration of 0.08 g / cm3. The combination of hair fiber and resin is 62% by weight of hair fiber and 38% by weight of resin. The combination has an average total density of 0.13 g / cm3. The mat has a hair parameter, P, as defined in the above, of only 0.1 g / cm3. The present inventor found that (a) such a low hair fiber concentration in combination with the low bulk density and low hair parameters provide the mat with a high resistance to abrasion, and (b) even if such hairs are relatively high have a dense layer of resin at the uppermost ends of the hair (for example, with all of the resin in the top 1 mm of the hair), such a resin / hair layer is stretched and detached by strong abrasion. Increases in the abrasion resistance of such mats can improve their utility. Watt et al., US Patent 4,808,458 discloses flocked pile fabrics in which a foamed resin is placed mainly in the lower 75%, preferably in the lower 50% of the hair what is the remainder of the hair almost free of resin, with the purpose of obtaining a suede effect. Such products are not effective in resisting severe surface abrasion. Zafiroglu, International Application Publication WO 94/19523 describes a non-woven fabric impregnated with abrasion-resistant resin. The fabric is manufactured by shrinking a non-woven fibrous layer to cause groups of the fibers to curl out from the plane of the layer to form "U-shaped" curls that generally protect vertically from the layer and then impregnate the layer contracted with resin. Typically, within the non-woven fibrous layer, the fibers are placed in all directions. The individual fibers in the curls of the fibrous layer with curls are therefore not placed in a direction generally perpendicular to the contraction, but rather it is placed in all directions within the curls of the fibrous layer woven with curls. Even though the fiber groups form vertical U-shaped curls, a large fraction of the fiber within the curls is not yet oriented perpendicular to the plane of the layer. Resin impregnation of such contracted fibrous layers provides a composite sheet having an abrasion resistance that is superior to a flat nonwoven layer impregnated with resin (without shrinkage or curl), but further improvements in strength are desired. the wear. An object of the present invention is to provide a composite sheet having a very high resistance to severe abrasive wear.

BRIEF DESCRIPTION DB LA BIVENCIÓ The present invention provides a composite sheet resistant to abrasion. The sheet has an upper surface and a lower surface and comprises a resin, groups of hair-like fibers and a network fibrous flat. The fibrous network is located between and is substantially parallel to the upper and lower surfaces of the composite sheet. The groups of hair-like fibers are located between the upper and lower surfaces and are mechanically connected to, and protrude in a generally perpendicular manner from the flat fibrous network. The composite sheet has a stretching capacity in any direction that is no more than 25%. The groups of hair-like fibers have an effective hairs concentration, of at least 0.10 g / cm 3, preferably in the range of 0.15 to 0.4 g / cm 3, and are surrounded and immobilized by the resin in the position generally perpendicular. Typically, the resin constitutes from 30 to 90%, preferably at least 50% of the total weight of the composite sheet. The groups of hair-like fibers and the flat fibrous network are made up of textile decitex fibers (ie, dtex 0.7 to 20). In addition, the hair fiber / resin layer has a thickness in the range of 0.5 to 3 mm, preferably 1 to 3 mm, and a total density, d, of at least 0.4 g / cm3, preferably in the range of 0.5 to 1.2 g / cm3, a stretching capacity in any direction not greater than 25%, preferably not greater than 10%, a vertical compressibility not greater than 25% r, preferably not greater than 10% and a hair parameter P, calculated by the equation, P = [cef £) (d)] 1/2, of at least 0.3 g / cm3, preferably at least 0.35. Typically, the hair fiber / resin layer has a unit weight that is in the range of 500 to 2,500 g / cm2. The composite sheet surface is abrasion resistant and is subjected to abrasion at no more than 50 micrometers per 1,000 abrasion test cycles with Wyzenbeek 40 grain. The invention also includes a process for making an abrasion resistant composite sheet that comprises (a) provides a fabric in which the fibers form or can form groups of hair-like fibers in a surface layer of 0.5 mm to 3 mm in thickness and which groups similar to fiber hairs are generally placed perpendicular to the surface of the fabric and one end of each group similar to fiber hairs is mechanically attached to, or protrudes through, a generally horizontal fibrous network, (b) contacting the area of the fabric by a factor of at least two and usually not greater than 1 factor of 15, preferably by a factor in the range of 3 to 12, to vertically twist and orient groups of fibers on the surface and to increase the 'group concentration generally perpendicular to hair-like fibers up to a concentration of at least 0.10 g / cm 3, preferably in the range from 0.15 to 0. 4 g / cm3, (c) immobilize the groups similar to fiber hairs in a generally perpendicular position by incorporating a resin in the surface layer and providing the layer with a total density of at least 0.4 g / cm3 and a hair parameter , P, of at least 0.3 g / cm 3, the resin forms part in a range of 30 to 90% of the total weight of the surface layer, and (d) optionally further stabilizing the dimensions of the composite material by joining non-elastic elements to the composite sheet. The invention additionally provides a shaped article having a composite abrasion resistant sheet bonded to at least a portion of the surface of the article. The composite sheets provide the surface layers that are capable of withstanding an abrasion test with Wyzenbeek grain 40 (as described in the following) with a loss in thickness of not more than 50 microns / 1,000 cycles.

BRIEF DESCRIPTION OF THE D-STATUS The invention will be better understood by referring to the accompanying drawings. Figure 1 schematically represents an enlarged and idealized cross section of an abrasion resistant surface layer of the invention, in which the fiber groups Hairs similar to hairs are in the form of inverted U-shaped curls, generally vertical, of a height H and a base B, curls 10 which are mobilized in the resin 15 between the upper surface 17 and the lower surface 18 of the impregnated fibrous layer. with resin. The curls 10 are generally perpendicular to the upper surface 17 of the layer and the contracted elements 20 are generally parallel to the surfaces 17 and 18. The surface 17 is the surface that is designed to be exposed to the abrasive conditions. Figure 2 represents a segment 11, of a yarn or a bundle of fibers in a fibrous non-woven layer, before twisting or contracting the yarn or the layer, the segment being between the stitches of fixed points 12 and 13; which are at a distance S separated. Figure 3 and 4 respectively represent the segment 11 after the fibrous fabric or layer in which they are located is contracted by a factor of 2 (figure 2) or three (figure 3) in the direction of the length in the segment . Note that the greater the contraction, it is accompanied by a greater verticality of the bundles of fibers or threads.

DETAIL DESCRIPTION TOÜ TAfl The following description of the preferred embodiments are included for purposes of illustration and is not considered to limit the scope of the invention; the scope is defined by the appended claims. As used herein, the terms "hair-like fiber groups" or "hair-like fibers" include twisted yarns, inverted U-shaped curls formed from twisted non-woven layers of textile fibers, flocked yarns and the like. . The fibers within each of these groups of hair-like fibers, as well as the fibers of the fibrous non-woven layers, are of conventional textile decitex, specifically, decitex 0.7 to 20. The composite material of the invention highly resistant to abrasion, has a surface layer in which groups of hair-like fibers are stacked together and immobilized by a resin within the surface layer. The hair-like fibers generally project perpendicularly from a fibrous network that is also located within the surface layer, for example, in the midplane or at the base of the layer. The fibrous network can be a fibrous non-woven layer, a fabric knitted, a woven cloth, or the like. Typically, as shown in Figure 1, the fibrous web 20 is located no further than 3 mm from the outer surface 17 of the layer to be exposed to abrasion. The resin 15 and the fibrous web 20 prevent the hair-like fibers 10 from moving side to side or collapsing in the layer when the surface of the composite material is subjected to lateral and normal forces during repeated abrasion or rubbing cycles. . The composite material has a stretchability and the resin / hair fiber layer has a compression capacity (measured as described below), each of which is no more than 25%, preferably no more than 10% . The stretching and compression capabilities, respectively, are measures of how much the fibers can move from one side to another and how much the fibers can be collapsed from their perpendicular position when the composite material is subjected to severe abrasion conditions. According to the invention, the surface layer of the abrasion-resistant composite material has a thickness in the range of 0.5 to 3 mm. Thickness of more than 3 mm is avoided because it is difficult to immobilize and stabilize hair-like layers if the surface to be subjected to abrasion is greater than 3 mm away from the horizontal fibrous network. The effective concentration ce ££ of - The fibers which are similar to generally vertical hairs within the surface layer are in the range of 0.1 to 0.5 g / cm3, preferably in the range of 0.15 to 0.4 g / cm3. In the surface layer of the composite material, the resin constitutes 30% to 90%, preferably at least 50% and more preferably at least 70% of the total weight of the layer. The total density, d, of the surface layer is at least 0.4 g / cm3. For high resistance to abrasion and wear, the surface layer of the composite material has a "hair parameter", P, which is at least 0.3 g / cm3. The hair parameter, P, as defined herein, is the square root of the product of the hair-like fiber concentration and the total density of the surface layer. The hair parameter is expressed by the formula P = [(c) (d)] 12. Typically, the surface layer of a composite sheet of the invention is not completely filled with resin and fiber. The layer can contain many small holes. A total surface layer density of at least 0.4 g / cm 3, and generally no greater than about 0.9 g / cm 3, automatically implies the presence of voids in the surface layer constituting at least 10%, and up to about 65% or more of the total volume of the layer, because most of the fibers and resins suitable for use in the invention have densities of at least 1.0 g / cm3. However, densities as high as 1.2 g / cm 3, and consequently, resin densities of more than 1.0 g / cm 3 are contemplated for use in the invention. For composite sheets of lighter and more flexible weight, a surface layer with hollow volumes of 25 to 75% is preferred. Usually, large amounts of resin are used in composite materials that have low concentrations of vertical fibers in the surface layer. For example, in composite sheets of the invention having effective concentrations of hair fibers close to the lower limit of 0.1 g / cm 3, a resin layer constituting 70 to 90% is preferred. For relatively high effective hair fiber concentrations, lower percentages of resin (eg 30-50%) may be used. Various types of resins are suitable for immobilizing fibers or bundles of fibers in a generally vertical position. Particularly useful polymer resins include polyurethanes, epoxy resins, synthetic rubbers, polyesters, polyacrylates, polyethers, polyether esters, polyamides, copolymers and mixtures thereof, and the like. The resins can be thermoplastic or thermoset. Very soft resins, for example, soft rubber latexes or resins that are highly foamed, are generally not suitable for use in the present invention. Resins suitable for use in the invention adhere well to the fibers and are usually well distributed through the hair fiber layer. However, if the distribution of the resin is not distributed completely uniformly across the layer of hair fibers, preferably the resin is concentrated near the surface to be subjected to abrasion with respect to the mechanically attached end. to the horizontal fibrous network. The resins can be applied to the hair fiber layer in any of several conventional ways such as, for example, by dipping, spraying, calendering, applying with a doctor's blade or other such techniques. The resin can be applied from a solution, dispersion or suspension or by function of a layer of the resin and forcing it into the vertical fiber layer. The resin can also be introduced as adhesive particles or as binding fibers that are activated by heat or by chemical substances. Conventional coagulation and / or foaming techniques can also be used for the application of the resin. In most cases, the resin or binder can be introduced into the fibrous layer before, during or after the shrinking step which is required according to the process of the invention to obtain the desired density of fibersverticals in the surface layer. However, when the surface layer is formed and the resin is incorporated, care must be taken to avoid bending the fibers from their vertical position and avoid immobilizing the fibers before the fibers have been placed vertically. After the incorporation of the hair-like fiber layer, the resin is dried and / or cured by conventional methods. If during the application of the resin, the layer of hair-like fibers is compressed in thickness up to 25%, the hair-like fibers can sometimes be flexed significantly with respect to verticality and result in a composite sheet having a decreased abrasion resistance. The surface layer of a composite sheet of the invention is much more resistant to abrasion than a 100% resin layer that does not contain vertical fibers or a resin / fiber surface layer in which the fibers are not in an upright position . For example, the composite materials of the invention have vertical fibers included in a layer of relatively soft polyurethane resin can be 50 to 150 times more resistant to abrasion than a layer made of 100% of the same resin. When using harder resins, and relatively more resistant to wear, the advantage of the fiber / resin layer of the invention on a layer of 100% of the Same resin is not big. However, in comparison with the surface layers that do not contain fibers or that contain mainly horizontal fibers, the surface layers of compounds of the invention will still be much more resistant to abrasion. In the process of the invention, the first stage provides a fabric having, or having the ability to form a layer of hair-like fibers. As used herein, the term "hair-like fiber layer" means a surface layer of a fabric from which the fibers are generally placed vertically relative to the surface of the fabric. According to certain embodiments of the process of the invention, the generally vertical fiber layer is derived from a substantially unstressed fibrous nonwoven layer which is subjected to a shrinking step which causes the fibers or groups of fibers to be curled towards outside the flat surface of the fibrous nonwoven fabric to form the hair-like layer. The generally vertical fibers of the hair-like layer are shown in Figure 1 and often appear as inverted curls in a U-shape, height H and base B. Such curls, when formed in part from a non-woven material fibrous not stitched, typically have an average separation (ie, a base B) in the range of 0.1 to 2 mm, and a Height ratio based on at least 0.5. The separation of the curl as small as 0.1 mm and proportions of height to base as large as 15 can be obtained when the layer is highly contracted (for example by a factor of 10 or 15) and additional elements capable of forming hairs or fibers are included. similar to hairs (for example, other non-elastic threads in knitting patterns). The practical ways to determine the H and B dimensions of the curls are described below in the paragraphs of the test methods. A typical non-woven fibrous layer for use in one embodiment of the process of the invention is a substantially non-woven, soft, thin network of short fibers or continuous filaments of textile decitex. These fibrous materials are collectively referred to herein as "fibers." The fibers occur naturally or are formed from synthetic organic polymers. Fibers that are smaller than 5 dtex and larger than 5 mm are preferred. Preferred fibrous layers are capable of curling over a relatively short range (e.g., as small as 1 mm) and typically weigh in the range of 15 to 100 g / m2, preferably less than 60 g / m2. Suitable materials for the initial nonwoven fibrous layer include air-laid webs, wet-laid webs, spun webs, webs joined by stitching and similar. Generally, felts and thick plush fabrics, similar adhesive or thermally bonded networks are not suitable; such materials are often difficult to curl at short intervals. The shrinkage and information of curls of the fibrous layers can be carried out in various ways. For example, an element that can be contracted, or an array of elements that can be contracted, can intermittently join the fibrous layer. The separation between the joint positions is typically at least 1 mm to allow efficient ripple. Subsequently, the element or arrangement of elements is caused to come into contact so that the area of the fibrous layer decreases significantly and the fiber groups are curled in the plane of the layer. Before the contractible elements are joined, an additional activation or contraction can be imparted to the initial fibrous layer by overfeeding the layer to the apparatus being used to join the elements that can contract. Many types of elements that can be contracted are suitable for use in the present invention. For example, the fibrous non-woven layer can be joined by stitching with elastic threads under tension. Stretched textured threads, covered or bare spandex threads and the like are threads suitable for sewing with element that can be contracted After stitching, the tension can be lightened to cause the desired shrinkage and curling of the fibrous layer. Instead of the stitching, the stretched elastic elements in the form of twisted, cross-wound, films or the like can be intermittently joined to the fibrous layer by hydraulic entanglement, bonding by thermal adhesive spots, or the like. Subsequently, the tension in the extended elements can be released to cause the contraction of the layer and the ripple. Other types of elements that can contract, which shrink when treated with heat, humidity, chemical substances or similar, can be intermittently joined to the fibrous layer without initial tension or without extension in the elements. After the union, the contraction of the elements that can be contracted can be activated by the appropriate treatment. Another additional way of carrying out the shrinkage and curling of the fibrous layer involves intermittently joining the fibrous layer to a stretchable substrate, which is tensioned in a direction that transverse to the direction in which it is pulled. substratum. For example, certain substrates when stretched by 15% in one direction can automatically experience substantially irreversible contraction (ie, narrowing) in the transverse direction in an amount is 2 to 3 times the amount of stretching. Therefore, an appropriate intermittent bonding of a fibrous layer to a stretchable substrate before stretching and stretching operation, and then applying drawing forces to the combined layer and the substrate can significantly decrease the fibrous layer area and cause the curling of fiber groups as required by the process of the invention. In other embodiments of the invention, the fiber-like layers are derived from conventional yarns in a knitted or knitted fabric which is constructed with shrinkable elements. When the contractible elements contact, the area of the fabric decreases significantly and causes the conventional threads of the fabric to activate and curl and project in a vertical direction from the horizontal plane of the activated fabric. In another embodiment, the hair-like layer includes curls of fibers projecting from wrapped yarns which are wound loosely around the axis of the core which can be contracted from an elastic combination yarn. Generally, threads that can contract and curl provide layers similar to denser hairs than non-woven shrinky fibrous layers. After the resin is applied According to the invention, the resulting composite sheets made with rolled yarns have a higher resistance to abrasion compared to those made with crimped non-woven fibrous layers. In still further embodiments of the invention, a hair-like layer can be derived from a combination of a substantially unbonded fibrous non-woven fabric, shrunken, loosely wrapped yarns of a combination of yarn and / or a non-elastic yarn. not curly In those embodiments in which a hair-like layer is formed partially or totally from crimped yarns derived from woven or knitted cloth, the fabric or the wave is thick enough to allow satisfactory yarn curling. Typically, the crimped elements, before crimping, have a flat length of at least 1 mm. In still another embodiment of the invention, a fabric of fluffed hairs is contracted to increase the density of the tuft of hairs, for use in a composite sheet of the present invention. As used herein, a "combination yarn" means a yarn having a core that can be shrunk (eg, provided by an elastic or shrinkable yarn), recircled by a "wrap" of conventional yarn or a "covering" of yarn. not contractable. The wrap or cover yarn can be any fiber natural or synthetic The winding can be combined with the elastic core while the elastic core is under tension by conventional winding, winding, stacking, coating, entanglement by air jet, entanglement or the like. The core can be a thread or monofilament of any elastic material. Spandex strands are preferred. If the wrapping yarn is combined loosely or loosely (eg, less than 3 turns / inches) with a tensioned and stretched elastic core, when the tension is released, the core contracts and the wrapping yarn contracts and becomes tight. curl perpendicular to the nucleus. When a fabric is manufactured, knitted or stitched together with a combination of yarn under tension, when the tension of the combination yarn is released, the yarn contracts and the wrapping yarn forms curls that contribute to the hair-like fibers on the surface layer. However, if the wrapping yarn is wound too tightly around the elastic core, the combination yarn can not provide hair-like fibers to the composite sheet. In the step of contraction of the process of the invention, the area of the fabric from which the vertical fibers are derived shrinks by a factor of at least 2, preferably in the range of 3 to 10, and sometimes by such a high factor as 15. The layer of shrinkage is used before or during the application of the resin. The fabric can not be contracted after the resin has hardened. As a result of the shrinkage step, the concentration of fibers similar to vertical hairs in the surface layer of the fabric increases significantly. Subsequently, the fibers are immobilized in place by adding a resin to the surface layer, in an amount in the range of 30 to 90% of the total weight of the resin-containing layer (i.e., the weight of the resin and the fibers). fibers similar to hairs). Preferably, the resin amounts of at least 50%, and more preferably at least 70% of the total weight of the layer. Typically, the resin is evenly distributed through the layer of hair-like fibers. However, to the extent that the hairs-like fibers are immobilized in a substantially vertical position, the distribution of the resin may be somewhat non-uniform and there may also be a very large void fraction in the layer. The voids can constitute up to 75% or more of the total volume of the layer. Deconstructing the gap layer to completely fill the layer with resin is not necessary. In fact, the techniques for this purpose are avoided because the techniques often oppress the fibers excessively and bend the fibers from its vertical position. Fibers similar to vertical hairs in the resin / fiber layer are essential for an improvement in abrasion resistance provided by the composite sheets of the invention. In addition to the hairs-like fabrics described above, the composite sheets according to the invention can also be produced from other types of fabrics with hairs, such as fabrics with plush hairs, velvets, carpets and velor to the extent that the fabrics have a hair height and a concentration of hair fibers within the requirements of the present invention and the fabrics are capable of being combined with resin to produce a layer having a hair parameter of at least 0.3 g / cm3. Such initial fabrics typically have hair fiber concentrations in the range of 0.05 to 0.15 g / cm 3. In composite sheets made with such fabrics, the resin typically constitutes at least two thirds of the total weight of the hairspike / resin surface fiber layer. The total fiber density similar to hair / resin layer is generally at least 0.4 g / cm3, preferably in the range 0.5 to 0.9 g / cm3. Densities of larger hairs are preferred instead of smaller, because the greater density of hairs is more resistant to compression and deflection of hair fibers during the impregnation stage with resin, and finally it can lead to a layer with greater resistance to abrasion. The abrasion-resistant surface of the composite sheet of the invention is resistant to lateral stretching, and vertical compression. The stretching and compression capacity of the composite sheet can be controlled in various ways. The stretching capacity of the composite sheet is altered and to a large extent by the horizontal fibrous network to which the hair-like fibers are attached and from which the hair-like fibers protrude. An inherently non-stretchable fiber network, located within about 3 mm of the outer surface of the composite material, can impart a non-stretched condition to the resin fiber surface layer. For a low drawing and compression capacity, a hard resin is preferred, instead of a softer resin. The lateral stability of the composite sheet in any linear direction can also be obtained by joining substantially similar strips, films, sheets, webs, cross framing that can not be stretched on the back surface of the abrasion resistant layer. The connection can be made by any convenient means, for example by gluing, thermal bonding or the like.

The composite abrasion resistant sheets of the invention are suitable for use in many different articles. The sheets may be molded into various shaped articles, may be used as single or multiple layers, or may be attached by various means to the surface or portions of the surface of various shaped articles to provide articles with abrasion resistance. For example, the composite sheets of the invention are suitable for use on shoe upper parts, work gloves, automotive engine timing bands, leather-like clothing, athletic protective pads for indoor use, women's bags, bags, luggage. , suitcases, seating surfaces, etc. The more abrasion-resistant composite sheets of the invention are especially suitable for articles that are subjected to more demanding abrasion conditions, such as the toe, heel and / or shoe sole, the lower part of industrial bags that with they are often placed on concrete floors, support surfaces of interacting mechanical parts, soquer soccer balls, hard work boots, gloves, motorcyclist suit pads and the like.

Test Methods The following methods and methods are used to measure the various characteristics of the resin impregnated fabrics of the invention. In the composite sheets of the invention, which have fibers similar to vertical hairs formed by the twisting of a fibrous non-woven layer or by the twisting of segments of threads over short intervals, the inverted U-shaped loops are formed from twisted groups of fibers or from twisted threads. The height H and the base B of the U-shaped curls of the twisted groups of fibers are determined from enlarged microphotographs (for example 15-20 X) of the cross sections of the curls taken through the curls in a plane perpendicular to the plane of the fibrous layer. The data is then used to calculate the H / B ratio. A low magnification microscope with strong upper and / or back illumination in the sample allows direct measurement of H and B. Usually, an average H-height of curl is equal to the thickness of a contracted fibrous layer. Alternatively, the average loop height H can be measured directly with a "touch" micrometer having a flat cylindrical zone of 0.64 cm (1/4 inch) in diameter which is applied at a load of 10. grams to the surface on which it makes contact. A digital micrometer, model APB-1D manufactured by Mitutoyo of Japan, is convenient for measurement. In addition to the method described above, the "verticality" of the hairs-like fibers can be determined by examination of an enlarged cross-section of the fiber / resin layer. If the curls are "compressed!" or they are "pushed down" excessively during the application of the resin, a relatively large flat portion of the inverted U is observed near the outer surface of the fiber / resin layer. The deflection of straight fibers or yarns from the vertical position can also be easily observed. Such severe deflection of hair fabrics can occur during the application of resin. A 30% decrease in the thickness of the pile fiber fabric during resin application can decrease the abrasion resistance of the final composite sheet, especially when the pile fiber concentration is close to the lower end of the concentration range. suitable for uses in the present invention. The stretching capacity, S, is determined by: (a) cutting a sample that measures 2 cm wide by 10 cm long from the composite sheet; (b) mark a standard length, L0, in the sample parallel to the long direction; (c) suspend a weight of 1.0 kilograms of the sample for 2 minutes; (d) with the suspended weight, re-measuring the "standard length", the length that has been remeasured is called Lf, and (e) calculating the stretch percent,% S by the formula% S = 100 (Lf - L0) / L0. The compression capacity, C, is determined by measuring the change in the thickness of the surface of the hair fiber / resin layer of the composite sheet (a) without pressure, t0, and (b) under a pressure of 351 kiloPascals (51 lb / in2), tf. A thickness gauge is used which imparts a load of 1.14 kg (2.5 pounds) on the hair / resin fiber material through a 0.64 cm (1/4 inch) diameter cylindrical foot. Then, the percent compression capacity,% C, is calculated by the formula% C = 100 (t0 t £) / t0. To avoid possible errors in these determinations, caused by the presence of a compressible horizontal fibrous network within the impregnated layer and to ensure that these are the characteristics of the hair fiber / resin layer that have been measured, the horizontal fibrous network is carefully remove by polishing until only the hair / resin layer remains. The unit by weight of a fibrous layer fabric is measured according to ASTM method D 3776-79. The density of the fabric impregnated with resin is determined from its unit weight and its measured thickness. The empty fraction of the layer can be easily determined from the measurements of the total density of the layer and the weights and densities of the fiber and resin in the layer. The rate of overfeeding, the contraction rate and the total fold are parameters reported herein which are measures of how much an initial fiber layer contracts or folds as a result of the operations to which the layer is subjected. The supercharging ratio, which applies only to the embodiments of the invention which use a twisted non-woven fibrous layer, is defined as the ratio of the initial area of the initial fibrous nonwoven layer to the area of the immediately current layer. upstream of a first processing stage (for example, a stitching joining stage). Overfeeding causes twisting, bending or compression of the non-woven layer in the direction in which it is fed into the operation. The shrinkage ratio is a measure of the amount of additional shrinkage the non-woven layer experiences as a result of the specific orientation to which it is subjected (for example, at the seam joint and tension release they form yarns in which intermittently join the fibrous layer). The contraction rate is defined as the area of the fibrous layer as it enters the specific operation divided between the area of the fibrous layer that leaves the specific operation. The total folding is defined as the product of the proportions of supercharging and contraction. The fraction of the original area is the reciprocal of the total folding and is equivalent to the proportion of a final area of the fibrous layer with respect to the initial area of the initial fibrous layer. The effective concentration of hair fibers is determined from the concentration of fibers within the surface layer of the composite sheet which are vertical (or hair-like) with respect to the surface to be exposed to abrasion. For fabrics in which the hairs-like fibers are derived from hard twisted yarns (for example, as in a knitted cloth contracted), the hair fiber concentration is the weight of the hard yarns in a unit area divided by the thickness of the layer. Similarly, if the hair-like yarns are provided by twisted yarns that have been wrapped loosely around a stretched elastic yarn and allowed to contract as the total weight of the twisted yarns is included in the calculation of the yarn. concentration of the hair strands, but the weight of the elastic core is not included. For composite sheets in which the hair-like yarns are formed from a contracted non-woven fibrous layer and Twisted, only 50% by weight of the non-woven fibrous layer is included in the calculation of the hair fiber concentration. The present inventor empirically found that the data of abrasion resistance versus hairs parameters for composite materials of the invention correlate much better when only half the weight of the twisted non-woven fibrous layer is used instead of the full weight of the layer. This reflects the fact that the hairs-like fibers formed by hard twisted yarns and fluffed yarn fibers, for example, are more effective in providing abrasion resistance to the composite sheet compared to hair-like fibers formed from fibrous non-woven layers contracted and twisted. Therefore, the effective concentration of hair fibers, cef £ = 10 ~ 4 kw / t, where k is 0.5 for hair-like fibers provided by the twisted non-woven fibrous layer, and 1.0 for twisted or plush yarns, w is the unit by weight of hairs similar to hairs in grams per square meter and t is the thickness of the surface layer, in centimeters. To determine the abrasion resistance of the samples, a "Precision Wear Testing Meter" Wyzenbeek, manufactured by J.K. Technologies Inc. of Kankakee, Illinois, is used with a 40-mesh de-grain fabric wrapped around the oscillating drum of the test equipment. The drum is oscillated back and forth across the face shows at 90 cycles per minute under a load of 2.7 kg (6 pounds). The test is carried out in accordance with the general procedures of ASTM D 4157-82. The thickness of the sample is measured with the thickness gauge mentioned above, before and after a given number of abrasion cycles to determine the rate of wear, in micrometers lost per 1,000 cycles. In order to provide adequate wear resistance to the composite sheets of the invention, a wear rate of not more than 50 microns / 1000 cycles is considered satisfactory.

EXAMPLES In the following examples, the manufacture and abrasion resistance of the various composite sheets of the invention are illustrated and compared with similar composite sheets that are outside the invention. The composite sheets of the invention are much more resistant to abrasion than composite comparative sheets. Samples of the invention are designated with Arabic numerals and comparison samples with capital letters. The conventional mesh warp nomenclature is used to describe repetitive sewing patterns particular that are used to prepare the various fabrics or fabrics joined by stitching the examples. A table accompanies each example of the detail records of manufacture, weight, compositions and characteristics of each composite sheet, as well as the abrasion performance of the sheet. In the examples, the fabrics are manufactured with elastic threads in which, in sequence (1) they are removed from the fabric-forming machine (2) they are allowed to reach an initial contraction (3) they are subjected to a "scouring" treatment when immersed in boiling water (100 ° C) for 1-2 minutes, (4) they are dried and subsequently (5) are set or hardened by heat in a tensioner frame for 1-1.5 minutes at 193 ° C (380 ° F) ). The particular amounts of stretching in the longitudinal and transverse directions during heat setting are used to control the final amount of shrinkage experienced by the fabric. Two different types of polyurethane resin are used to impregnate the hair-like layer of the composite samples. "ZAR", a clear polyurethane finish sold by United Gilsonite Laboratories of Scranton, Pennsylvania, referred to herein as "PU-1", is used for the sample of Examples 1 and 3. PU-2, a polyurethane resin softer, sold by KJ Quinn Se Co., Inc. of Seabrook, New Hampshire is used for all the remaining examples. PU-2 is a two-part formulation that is mixed, applied to the hair fibers and then cured. The samples are impregnated by resin by conventional immersion techniques. The applied resin becomes more regular with a doctor's blade and is dried and / or cured with hair fibers oriented downward for at least 12 hours in a hot air oven. The temperature of the oven is maintained at 65 ° C for fabrics impregnated with PU-1 and at 95 ° C for fabrics impregnated with PU-2. The compression capacity, density and abrasion wear rate with grain 40 (in micrometers / 1,000 cycles) and Shore A hardness of a 5 mm thick layer of each resin containing no fibers is as follows: Ejep-plo 1 This example compares two samples of compound sheets impregnated with resin of the invention with one it shows that it is outside the invention. In each sample, the hair-like fibers are formed from Kevlar aramid fibers (sold by E. L. Du Pont de Nemours &Co.). In sample 1, hair-like fibers are formed by twisting Kevlar ™ yarns into a woven fabric. In sample 2, the hair-like fibers are formed by twisted Kevlar ** twisted yarns and a twisted, non-woven Kevlar fibrous substrate in a seam-bonded fabric. the invention due to its low concentration of effective hair fibers and a low hair parameters, the fiber-like groups are formed solely from a non-woven and twisted layer of Kevlar fibers. Samples 1 and 2 of the invention are shown to have between about 3 to 5 times the abrasion resistance of the comparison sample A. The initial fabric for the composite sheet of sample 1 is a woven fabric of two vines that is prepared with a "Liba" machine that operates at 10 gauge (10 rows per inch or 4 per centimeter) and 8.7 courses per centimeter .22 courses per inch). The black bar is threaded with 400 den (440 dtex) filament Kevlar ^ -thread 29 forming a repeated pattern of 1-0.4-5 stitches. The front bar is threaded with a combination of yarn that is considered to be 280 den (320 dtex) of Lycra spandex elastic core, around the which is firmly attached, to approximately 2.8 turns / centimeters (7 turns / inches) with a 70 den (78 dtex) detexturized polyester yarn of filament 34. When removing the woven fabric from the LIBA machine, the fabric as it is woven is it weighs 159 g / cm2. The fabric as it has been woven is then scorched and heat set. As a result, the fabric shrinks by a factor of 2.6 and increases its weight to 413 g / m2. The thread of the back bar is twisted to form groups of fibers similar to hairs in the form of an inverted U shape. The narrow winding of the yarn combination of the front bar yarn does not contribute to the formation of hair-like groups of the fibers. Later, the fabric is impregnated with PU-1 polyurethane resin and dried and cured in a hot air oven. The characteristics of the resulting composite sheet, sample 1, is recorded in table I below. The initial fabric for the composite sheet of sample 2 is a two-bar seam joined fabric that has been prepared with a width of 3.6 meters (140 inches), with a two-bar "Liba" machine adapted for seam joining. a fibrous non-woven fabric. Each bar is threaded to 14 gauge (5.5 rows / centimeter, or 14 rows / inches) and 3.5 stitches / cm are inserted (9 stitches / inches) in each row. A fibrous substrate bonded by sontara yarn "of 34 g / m2 type Z-ll (manufactured by E. I. Du Pont de Nemours & Co.) of Kevlar ™ 29 aramid fibers of 1.5 den (1.7 dtex) per filament 2.2 cm in length is fed to the LIBA machine with 47% supercharging. The stitch yarns of the back bar and the front bar are the same as those used for sample 1, but formed in atlas stitch patterns from two opposite courses. When removing the cloth-bound fabric from the LIBA machine, the fabric comes in contact with an area and increases its weight to 184 g / m2. The stitch-bonded fabric is then scoured, heat-set and impregnated with resin in the same manner as for Example 1, except that the area of the boiling sample 2 and the heat set shrinks by a factor of 2.9 and the fibrous non-woven layer, in which it has been supercharged in the stitch-joining stage, experiences a total folding of 4.3. Additional details of the fabrication and characteristics of sample 2 are listed in table I below. A composite comparison sheet, sample A, is prepared from the same type and weight of initial cloth bonded by Kevlar spinning "which is used for the sample 2. A stitch binding machine of a rod, threaded to 12 gauge (4.7 needles / centimeter or 12 needles / inches) and inserting 5.5 stitches / centimeter (14 stitches / inches) is used for comparison sample A. The fibrous layer Nonwoven is overfed 25% and sewn with the same combination yarn as used to prepare samples 1 and 2. A repetitive stitch pattern 1-0.2-3 is used. Sample A is impregnated with resin, screened and heat set in the same manner as samples 1 and 2. The details of comparison sample A are summarized in table I. The data in table I clearly show the superior resistance to abrasion of the samples of the composite sheets 1 and 2 with respect to the composite comparison sheet of the comparison sample A. Samples 1 and 2, respectively, were 2.7 and 3.1 times more resistant to abrasion compared to sample A.

Table I (Example 1) Identification of sample 1 2.? initial materials nonwoven weight, g '/ m2 0 34 34 supercharging ratio na 1.47 1.25 hard yarns, weight g / m2 135 104 0 weight of shrinkable materials, g / m2 24 30 44 total weight, g / m2 159 184 87 Folding contracted weight, g / m2 413 537 361 shrinkage ratio 2.6 2.9 4.15 non-woven weight, g / m2 0 145 176 hard yarn weight, g / m2 351 302 0 total non-woven folds na 4.3 5.2% of the original area 38 35 24 Resin application resin weight, g / m2 306 566 510 % loss of hair height 0 0 0 Characteristics of the surface layer total weight, g / m2 657 1013 686 thickness, mm 1.1 2.0 1.4 density, g / cm3 0.59 0.51 0.49 weight of the hair fiber, g / m2 351 445 176 concentration of the hair fiber, g / cm3 0.32 0.23 03 effective hair concentration, g / cm3 0.32 0.19 O.OEB hair parameters, P, g / cm3 0.44 0.32 0.18 curl base, B, mm 0.7 0.5 0.4 curl ratio H / B 3.6 5.0 3.5 Resin weight% 46 56 74% of holes 51 58 59 % stretch capacity 10 10 10% compression capacity 10 10 5 Abrasion resistance grain 40 test duration, 103 cycles > 5 > 5 > 5 wear, micrometers / 103 cycles 23 36 110 % normalized wear * 21 33 100 Note: na = not applicable; * = normalized for sample A.

Ejqapl? -2.

In this example, several samples of composite sheets of the invention and comparison samples similar to those of Example 1 are prepared, but with softer PU-2 polyurethane resin replacing the PU-1 polyurethane resin of Example 1. Each sample and comparison sample has groups of hair-like fibers formed from Kevlar aramid fibers. * Sample 3, sample 4 and comparison sample E, respectively, contain the same fabrics as samples 1 and 2 and sample A example comparison 1. The composite sheet of Example 3 includes a contracted fabric that has been woven with an elastic combination yarn in a bar, and a non-elastic yarn in the second bar. The composite sheet of the sample 4 includes a contracted fabric that has been prepared by stitching together a fibrous layer with a bar of elastic composite yarn and a non-elastic yarn bar. The sample E includes a contracted fibrous layer which has been prepared by seaming the layer with a single bar of elastic combination yarn. The additional composite comparative sheet of samples B and C, respectively, are made with the same initial fabrics as samples 3 and 4, but with different amounts of resin applied. Table II summarizes additional details regarding the fabrication, characteristics and performance of the resulting composite sheet sample when abraded. Table II clearly shows that the advantage of abrasion resistance of composite sheets manufactured with high value hairs parameters. See, for example, the results of the abrasion test for sample 3 compared to sample B and sample 4 compared to sample C. In addition, abrasion wear results for these samples, and sample E, compared to the corresponding samples in example 1 show that to the extent that the resins immobilize the fibers and they provide low compression and stretch capacity to the layer, an increase in the hardness of the resin apparently does not increase the abrasion resistance of the composite materials of the invention. Increases in the concentration of hair fibers and a hairs parameter are more effective. In addition to the composite sheets described above containing fabrics with groups similar to Kevlar aramid fiber hairs, two additional composite sheets, sample 5 and comparison sample D are prepared.The initial fabrics for these two samples are manufactured by filling a yarn of 1,000 den (1,100 dtex) of Kevlar®-29 into a non-woven polyester fabric, bound by Reemay * yarn, lightly bonded, of 119-g / m2 (manufactured by Reemay, Inc., of Old Hickory, Tenn.) At 5.1 plush / centimeters (16 plush / inch) and 14 gauge (5.5 plush / centimeter needles or 14 plush / inch needles) The plush fabric is stretched 20%, with an accompanying narrowing of approximately 40% , to contract the area of the fabric by a factor of 2. Table II summarizes additional details of the construction and operation of the composite sheet.

Table TT (Example 2) Identification of the sample initial materials nonwoven weight, g / m2 0 0 34 34 119 119 34 supercharging ratio na na 1.47 1.47 na na 1.25 hard yarns, weight g / m2 135? r-5 104 104 205 205 0 weight of shrinkable materials, g / m2 2 24 50 30 0 0 44 total weight, g / m2 159 159 184 184 314 314 87 Folding contracted weight, g / m2 413 413 537 537 636 636 631 contraction ratio 2.S 2.6 2.9 2.9 2 0 2.0 4.15 nonwoven weight, g / m2 0 0 145 145 0 0 176 weight of hard yarn, g / m2 351 351 302 302 415 415 total nonwoven folding na na 4.3 4.3 na na 5.2% of the original area 38 38 35 35 49 49 24 Resin application Resin weight, g / m2 646 102 1263 192 1680 560 1020 % loss of hair height 0 0 0 0 0 0 0 Characteristics of the surface layer total weight, g / m2 997 453 1710 639 2095 975 1196 thickness, mm 1.1 1 1 2.0 2.0 2.6 2.6 1.1 density, g / cm2 0.91 0.41 0.86 0.32 0.81 0.38 1 08 weight of hair fiber, g / m2 351 351 447 447 415 41S 176 concentration of hair fiber, g / cm3 0.32 0 32 0.22 0.22 0.16 0.16 0.16 effective concentration of hairs, g / cm3 0.32 0 32 0.18 0.18 0.16 0.16 0.08 hairs parameters, g / cp -3 0.54 0.36 0.40 0.24 0.36 0.25 029 r zo base, B, mm 0.7 0 7 OS OS 0.8 0.8 0.4 ripple ratio H / B 3.6 3 6 5.0 5.0 3 8 3.8 3.S % by weight of resin 64 22 74 30 80 57 85 % of holes 24 66 28 72 32 68 10 % stretch capacity 0 20 0 15 0 0 0 V compression capacity 0 15 0 15 0 0 0 Abrasion resistance of grain 40 test duration, 103 cycles 13 1.5 25 7.9 25 6 13.2 wear, micrometers / 103 cycles 18 80 25 66 30 60 50 % normalized wear * 36 160 50 132 60 120 100 Notes: * = normalized for sample E; na = not applicable. io_a This example further illustrates the strong effects of the total folding and the concentration of hair-like fibers on the abrasion resistance of the composite sheets of the invention. The composite sheets of samples 6, 7 and 8, and a comparison sample F each contain a layer in which the hairs-like fibers have been derived from both a twisted fibrous non-woven layer and twisted non-elastic knitted yarns. . In comparison sample G, twisted non-elastic yarns are not present. To prepare the initial fabric for each sample, a fibrous layer of 26 g / m2 of fabric bonded by sontara spinning "8017 unbound polyester fibers is overfeeds in a "Liba" stitching machine with two bars. The front bar of the Liba machine forms a repeated pattern of 1-0.2-3 stitches with a combination yarn that has an elastic core of Lycra spandex "of 280 den (311 dtex), it is rolled tightly to 3.5 turns / centimeter (9 turns / inches), with a 70 den (78-dtex) filament polyester thread 34. Except for the comparison sample G fabric, which did not use a back bar, the back bar forms a repeated pattern of 3-4, 1-0 stitches with a filament 34 of 210 den (233 dtex) of high tenacity of Dacron polyester yarn * 01 type 62. Lycra ^ and Dacron "* are sold, each, by DuPont. The Liba machine, a 14 gauge machine (5.5 needles / centimeter or 14 needles / inch), inserts 5.5 courses per centimeter (14 courses per inch). Different amounts of tension are imposed on the combination yarn used to prepare each sample with a different amount of shrinkage when the fabric is removed from the Liba machine. The contraction of the combination yarn causes a layer of hair-like fibers to develop. The hair-like fibers formed by shrinkage and twisting of the non-woven fibrous layer and the twisting of the non-elastic stitching yarns of the back bar, which is accompanied by the contraction of the combination yarn. Subsequently, after scouring fabrics contracted they are treated with heat in the frame of the tensioner to establish the final dimensions of the fabric. Subsequently, the fabric samples are impregnated with PU-1 polyurethane resin, the same resin that was used in Example 1, to immobilize the hair-like fibers. The impregnated samples are then dried to form the composite sheet sample. The details of the sample and the results of the abrasion test are summarized in Table III below.

Table III (Example 3) Identification of the sample a. initial materials nonwoven weight, g / m2 26 26 26 26 26 supercharging ratio 1.2 1.2 1.2 1.2 1.3 hard yarns, weight g / m2 71 71 71 71 0 weight of shrinkable materials, g / m2 31 31 31 31 32 total weight, g / m2 133 133 133 133 66 Folding contracted weight, g / m2 578 785 918 238 544 contraction ratio 4.4 5.9 6.9 1.8 8.2 nonwoven weight, g / m2 137 183 215 56 277 weight of hard yarn, g / m2 312 418 490 128 0 Total non-woven folding 5.3 7.1 8.3 2.2 10.7 % of the original area 19 14 15 45 2 Application of resin resin weight, g / m2 1043 884 655 499 986 % loss of hair height 10 9 15 8 or Characteristics of the surface layer total weight, g / m2 1489 1485 1360 683 1263 thickness, mm 1.8 2.0 1.8 1.4 1.6 density, g / cm3 0.83 0.74 0.75 0.50 0.79 weight of the hair fiber, g / m2 449 601 705 184 277 concentration of hair fiber, g / cm3 0.25 0.30 0.39 0.13 0.17 effective hairs concentration, g / cm3 0.21 0.25 0.33 0.11 0.085 hairs parameters, P, g / cm3 0.41 0.44 0.49 0.23 0.26 curl base, B, mm 0.44 0.30 0.25 1.0 0.30 curl ratio H / B 4.1 6.6 7.2 1.4 5.3% resin 70 60 48 73 78 % of holes 31 38 38 58 34 % stretch capacity 5 5 10 5 0 % compression capacity 10 5 10 15 0 Grain abrasion resistance 40 test duration., '103 cycles 23 31 25 2.3 16 wear, micrometer / 103 cycles 32 13 12 80 92% normalized wear * 35 14 13 87 100 Notes: * standardized for sample G .

Eiand ---_ i In this example samples of composite sheets are made from shrink fabric having single-bar fabric with an elastic combination yarn having a non-elastic twisted yarn that is wrapped loosely. The hairs-like fibers are formed from the coiled yarn when the combination yarn contracts. Samples 9, 10 and 11 and comparison sample H were each woven on a "Liba" machine of a bar forming a repeated pattern of 1-0.2-3 stitches with a combination yarn having a spandex elastic core Lycra "1 * of 280 den (311-dtex) with an elastic core wound loosely to approximately 0.6 turns / centimeter (1.5 turns / inches) with a filament 34 of 70 den (78 dtex) of textured polyester yarn. sample is made with the Liba machine operating at 5.5 courses / centimeter (14 courses / inches), and the needle bar with 20 gauge (ie, 7.9 needles per centimeter or 20 needles per inch) .Except sample 11, the which was made to caliber 10. The fabrics for each sample are woven with the combination yarn under a different tension.When removing the fabric from the knitting machine and releasing the tension in the combination yarn and the area as it has been Fabric fabric shrinks by a factor of 11.5 to 14 times, with a curly accompanying yarn that has been wrapped loosely to form a hair-like layer. The PU-2 polyurethane resin, as used in example 2, is applied to the hair-like fibers of each sample. Additional details of sample manufacture and abrasion performance are listed below in Table IV, which also includes Sample G from Example 3 for additional comparison purposes. The abrasion test results listed in Table IV show that the high hairs concentrations and the high hairs parameters and the accompanying high abrasion resistance can be obtained with fabrics having groups similar to fiber hairs provided only by twisted yarns . The result also demonstrates the importance of avoiding the excessive stretching capacity in the composite sheet. Note that the hair-like fiber / surface resin layer of the composite sheet of the comparison sample H having a resin content of only 25% by weight is easily stretchable and shows 11 to 18 times higher abrasion rate than the sample 9-11 of the invention of composite sheet. Unless enough resin is incorporated into the fiber / resin layer, even if the other characteristics of the layer are in accordance with the invention, the composite sheet will still lack strength for stretching and abrasion. The abrasion resistance data and other details of the samples are summarized in Table IV and clearly demonstrate that the superior abrasion resistance of the composite sheets of the invention with respect to the comparison samples. The data again shows that the hair-like fiber layer impregnated with resin meets the requirements of the present invention and provides a composite sheet with a highly effective abrasion resistance.

Table IV (Example 4) Identification of the sample i 11 H initial materials nonwoven weight, g / m2 0 0 0 0 26 supercharging ratio na na na na 1.3 hardness of the threads, g / m2 0 0 0 0 0 weight of the coiled yarn, g / m2 24 24 21 24 0 contractable weight , g / m2 22 22 20 22 32 total weight, g / m2 46 46 41 46 66 Folded contracted weight, g / m2 557 557 476 557 544 shrinkage ratio 11.5 11.5 14.0 11.5 8.2 nonwoven weight, g / m2 0 0 0 0 277 total nonwoven folding na na na 10.7 weight of the coiling yarn, g / m2 276 276 294 276 0 % of the original area 8.7 8.7 7.8 8.7 12 Application resin resin weight, g / m2 910 1009 987 94 986 % loss of hair height 17 17 13 17 or Characteristics of the surface layer total weight, g / m2 1186 1285 1281 370 1263 thickness, mm 1.5 1.5 1.4 1.5 1.6 density, g / cm3 0.79 0.86 0.91 0.25 0.79 weight of the hair fiber, g / m2 276 276 294 276 277 concentration of the hair fiber, g / cm3 0.18 0.18 0.21 0.18 0.17 effective hair concentration, g / cm3 0.18 0.18 0.21 0.18 0.085 hairs parameters, P, g / cm3 0.38 0.38 0.44 0.38 0.26 curl base, B, mm 0.12 0.12 0.10 0.12 0.30 curl ratio H / B 12.5 12.5 14.0 12.5 5.3 Resin% 76 78 77 25 78 % of holes 35 28 24 79 34% of stretch capacity 10 5 5 80 0 % compression capacity 10 5 10 15 0 Abrasion resistance grain 40 test duration, 103 cycles 20 18 23 0.8 16 wear, micrometer / 103 cycles 30 40 43 450 92 % normalized wear * 33 43 47 489 100 Notes: * normalized with sample G.

In this example composite sheets impregnated with resin are prepared from fabrics subjected to warp in mesh of two contracted bars. The initial fabric for each of the samples 12-15 and the comparison sample I is knitted in a two-bar Liba machine, with a press bar with an elastic combination yarn having a non-elastic wrapping yarn that has been wrapped loosely and the second bar is threaded with a non-elastic textile yarn. The front bar forms repeated patterns of 1-0.2-3 stitches with spandex Lycra "11 of 280 den (311 dtex) around which they have turned or coiled loosely, at 0.4 turns / centimeter (1 turn / inches) , a 70 den (78 dtex) filament textured polyester yarn 34. The back bar forms a repeating pattern of 3-4.1-0 stitches with a conventional 150 denier polyester textile yarn (167 dtex). It is made with the Liba machine that operates at 5.5 courses / centimeters (14 courses / inches), except sample 12 and comparison sample J, which were made each with 8.7 courses / centimeter (22 courses / inch), and with the 20-gauge threaded machine, and sample 13, which was made with the 10-gauge threaded machine. The tension on the combination yarn used to prepare the Samples are adjusted so that when the woven fabric is removed from the Liba machine, it is scorched and heat set, the area as it is woven from the fabric shrinks by a factor of 1.9 to 7. The shrinkage of the fabric is accompanied by the contraction and twisting of a twisted yarn, loosely wrapped and twisted of the second yarn of bar. PU-2 polyurethane (same as in Example 2) is applied to each sample. The additional fabrication and abrasion performance details of the samples are summarized in Table V below, in which Sample G of Example 3 is also included for further comparison purposes. The abrasion wear results show that comparison samples G and I show between about 2.5 to about 20 times more wear abrasion than samples 12-15 of the invention. The hair-like fibers of the fabric of Sample I apparently folded from the vertical position during resin application, as indicated by the 31% loss in surface layer height and in the rate of insufficient shrinkage.

The results summarized in Table V show that shrinkage of the fabric of samples 12-15 of the invention results in fibers forming similar to substantially vertical hairs. The hair-like fibers are derived both from shrink wrapped yarn and yarn from the second twisted bar. In contrast, the fabrics of the comparison sample I do not provide a satisfactory layer similar to hairs and are not adequately impregnated with resin, and consequently, show a much lower abrasion resistance. Sample G, despite its very high resin density, does not provide high abrasion resistance due to the low effective hair density and low hair parameters.

Table V (Example 5) Identification of the sample 12 Ji li 15. initial materials nonwoven weight, g / m2 0 0 0 0 0 26 supercharging ratio na na na na na 1.3 hard yarns, weight g / m2 92 32 32 32 92 0 yarn weight woven, g / m2 33 23 23 23 26 0 weight of shrinkable materials, g / m2 28 22 22 22 26 32 total weight, g / m2 153 77 77 77 154 66 Folding contracted weight, g / m2 554 540 870 870 299 544 contraction ratio 3.6 7.0 11.3 11.3 1.9 8.2 nonwoven weight, g / m2 0 0 0 0 0 277 weight of hard yarn, g / m2 331 224 361 361 175 0 weight of the woven yarn, g / m2 118 161 260 260 49 0 total non-woven folding na na na na na 10.7% of the original area 28 14 9 9 53 12 Resin application resin weight, g / m2 826 1098 380 920 408 986% loss of hair height 16 4 15 0 31 0 Characteristics of the surface layer total weight, g / m2 1275 1483 1001 1541 632 -263 thickness, mm 1.6 2.4 1.7 1.9 1.3 1.6 density, g / cm3 0.65 0.74 0.59 0.81 0.49 0.79 weight of the hair fiber, g / m2 449 385 621 621 224 277 hair fiber concentration, g / cm3 0.28 0.16 0.37 0.33 0.17 0.17 effective hair concentration, g / cm3 0.28 0.16 0.37 0.33 0.17 Oj-E hair parameters, P, g / cm3 0.43 0.34 0.47 0.51 0.28 0.25 curl base, B, mm 0.3 0.3 0.2 0.2 0.3 0.3 curl proportion H / B 5.3 8.9 8.5 8.5 4.3 5.3. Resin% 65 74 38 60 65 78% of voids 46 38 51 33 59 34% stretch capacity 10 5 10 0 5 0 of compression capacity 10 5 10 0 25 Abrasion resistance grain 40 test duration, 103 cycles > 25 > 25 > 25 > 25 4 16 wear, micrometers / 103 cycles 28 40 8 5 100 92 % normalized wear * 30 40 9 5 109 100 Notes: na = not applicable; * = normalized for sample G.

Ejflpplo 6.

In this example, composite sheet samples are prepared which have been hair-like fibrous layers with hairpin needles, impregnated with resin. The initial fabrics for sample J and 16 are prepared from an air-laid network of 272 g / m2 of Dacron polyester fiber, type 54 of 7.6 centimeters long (3 inches) of 1.5 den (1.7 dtex) ( sold by EI Du Pont de Nemours S Co.) which is placed and knitted with fork-type needles on a Reemay 11"polyester fabric joined by 119 g / m2 of polyester fabric with a Dilo forks stitcher. stitcher has a 14 gauge machine (5.5 needles per centimeter (14 needles per inch)) that performs approximately 20 inserts per square centimeter (130 per insert per square inch). The fiber curls are formed on the surface of Reemay * which is opposite the side on which the needles enter the layer. The curls project approximately 2.5 mm above the surface of the ReemayMR fabric. The comparison sample J is screened, heat set, impregnated with PU-2 polyurethane and then dried. Sample 16 is treated in the same manner, except that prior to setting by heat, impregnation with resin and drying, sample 16 is stretched longitudinally by 30% with a corresponding decrease in approximately 37% of its original width to provide the sample with a contraction in area by a factor of 2.1. The additional fabrication details, characteristics of the samples and results of the abrasion wear test are summarized in Table VI. The summary also includes data for the comparison sample G of example 3, for additional comparison purposes. Table VI clearly shows that the composite sheet sample 16 of the invention, which contains a layer of hair-like fiber prepared by stitching with fork and shrinkage, is 6.5 times more abrasion resistant than a composite sheet prepared in a similar manner as It has a hair-like layer sewn with forks that has not been contracted. In addition, the composite sheet of the sample 16 is 4.5 times more resistant to abrasion than the composite sheet of the comparison sample G of example 3. These results, emphasize, as shown in the preceding examples also, that the hair parameter of the hair fiber layer impregnated with resin is very important to provide a composite sheet with resistance to the abrasion. The sample 16 of the invention has a hair parameter 0.37, while the comparison sample J and G, respectively, have hair parameters of 0.22 and 0.26.

Table VI (Example 6) Identification of the sample J. 16 G initial materials nonwoven weight, g / m2 272 272 26 supercharging ratio na na 1.3 weight of shrinkable materials, g / m2 119 119 32 total weight, g / m2 391 391 66 Bending contracted weight, g / m2 391 821 544 contraction ratio 1.0 2.1 8.2 non-woven weight, g / m2 272 571 277 total non-woven folds? .or 2.1 .7 % of the original area 100 48 12 Application resin resin weight, g / m2 720 930 986 % loss of hair height 0 0 0 Characteristics of the surface layer total weight, g / m2 992 1501 123 thickness, mm 2.4 2.5 1.6 density, g / cm3 0.41 0.60 0.79 weight of the hair fiber, g / m2 272 571 277 concentration of the hair fiber, g / cm3 0.11 0.23 027 effective hair concentration, g / cm3 0 0..1111 0 0..2233 OCEE hair parameters, P, g / cm3 0.22 0.37 0.2S curl base, B, mm 0.8 0.4 0.3 curl proportion H / B 3.0 6.0 5.3% by weight of resin 73 62 78 % of holes 65 50 34 % stretch capacity 10 0 0 % compression capacity 15 0 0 Abrasion resistance of grain 40 duration of the test, 103 cycles 5 15 16 wear, micrometers / 103 cycles 130 20 92% normalized wear * 141 22 100 Note: na = not applicable; * = normalized for sample G.

Example 7 In this example, two composite sheet samples are prepared with resin-impregnated velor fabrics that provide the hairs-like fibers for the resin / fiber layers. The initial fabrics for samples 17 and 18 are prepared with a width of 3.3 meters (130 inches), with caliber 70 (27.6 needles / centimeters or 70 needles / inches), 3-bar mesh warp machine which forms 25.2 courses per centimeter (64 courses per inch). A type KS3P machine is used, manufactured by Karl Mayer of Frankfurt, Germany. The first bar is pressed with flat 24-filament (ie, non-textured) polyester yarn of 70 den (77 dtex) and a repeating pattern of 1-0.1-1.2-1 stitches is formed. The second bar is pressed with a flat 40-filament polyester yarn of 100 den (110 dtex) and a repeating pattern of 1-0, 0-0, 1-1 stitches is formed. The The third bar is pressed with a flat 24-filament polyester (ie, non-textured), 70 den (77 dtex) yarn and a repeating pattern of 1-0, 0-0, 1-l stitches is formed. The velor fabric that is formed by the machine has a woven reinforcement layer (ie as a base) weighing 347 g / m2, and a layer of curled yarns measuring 1.5 mm high, weighing 231 g / m2 and an effective concentration of hair fibers of 0.18 g / cm3. Sample 17, in the condition as it is woven, is impregnated with PU-2 polyurethane resin. After curing the resin, the sample has a hair parameter of 0.31 g / cm3. The sample 18, in its condition as it is woven, is heat set at a temperature of 191 ° C (375 ° F) to stabilize the fabric dimensions, then the curls of the heat-set sample 18 are burst to provide a 1.2 mm hair thickness Sample 18 is also impregnated with PU-2 polyurethane resin, after which curing is also provided in the sample with a hairs parameter of 0.31 g / cm 3. As shown in the table VII, samples 17 and 18 are composite sheets of the invention that function quite well with grain 40 abrasion wear test. Comparison sample G of example 3 is also included in table VII for further comparison. with the composite sheets of samples 17 and 18 of the invention with velor fabrics impregnated with resin, the composite sheet of the comparison sample G with its shrinkaged and crimped non-woven fibrous layer, impregnated with resin, is abraded 2.2 to 2.4 times as rapidly as the samples. and 18.

Table VII (Example 7) Identification of the sample 2J. 13L initial materials Weight of base coat, g / m2 347 347 na hair weight, g / m2 231 231 na hair height, mm 1.5 1.5 na After setting by heat and shear "Weight of base coat, g / m2 347 347 weight of hair, g / m2 231 210 na of hair height, mm 1.5 1.4 na Resin application Resin weight, g / m2 452 422 986% loss of hair height 15 15 0 Characteristics of the surface layer total weight, g / m2 683 682 _Q3 thickness, mm 1.3 1.2 1.6 density, g / cm3 0.53 0.53 0.79 weight of the hair fiber, g / m2 231 210 277 concentration of the hair fiber, g / cm3 0.18 0.18 017 effective hair concentration, g / cm3 0.18 0.18 0.085 hairs parameters, P, g / cm3 0.31 0.31 025 curl base, B, mm 0.4 0.4 0.3 curl ratio H / B 3.3 3.0 5.3 % by weight of resin 66 67 78% of holes 45 44 34 % stretch capacity 10 0 0 % compression capacity 15 15 0 Abrasion resistance of grain 40 test duration, 103 cycles 16 15 16 wear, micrometers / 103 cycles 41 38 92 % normalized wear * 45 41 100 Notes: + Only for sample 18 was sheared, "na" means that it is not applicable, see table III (example 3) for more details on sample G. *% normalized wear for sample G.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. Having described the invention as above, property is claimed as contained in the following:

Claims (19)

1. An abrasion resistant composite sheet having an upper surface and a lower surface, and including a flat fibrous network located between and substantially parallel to the upper and lower surfaces, groups of hair-like fibers located between the lower and upper surfaces of the sheet, which are connected to and protruding generally perpendicularly from the flat fibrous web, a resin that immobilizes the groups of hair-like fibers in a generally perpendicular position and which constitutes, in a range of 30 to 90% of the weight total of the layer of hair impregnated with resin, the groups of fibers similar to hairs in the flat fibrous network are constituted of fibers or filaments of decitex textile, and the sheet has a capacity of stretching greater than 25% in any direction, the sheet compound is characterized in that, in combination, hair-like groups are present in the similar fiber layer r hairs impregnated with resin in an effective concentration of hair fibers, ceff, of at least 0.1 g / cm3, and the hair-like layer impregnated with resin has a thickness in the range of 0.5 to 3 mm, a total density, d, of at least 0.4 g / cm3, a unit weight in the range of 300 to 2,500 g / m2, a vertical compression capacity of no more than 25% and a hair parameter, P, calculated by the equation P = [(ceff) (d) ] 1/2, of at least 0.3 g / cm3.

2. The composite sheet according to claim 1, characterized in that the resin constitutes at least 50% of the total weight of the hair-like fiber layer impregnated with resin, the concentration of effective hair fibers is in the range from 0.15 to 0.5. g / cm3, the thickness of the layer is in the range of 1 to 3 mm, the total density of the layer is in the range from 0.5 to 1.2 g / cm3, the hair parameter is at least 0.35 g / cm3 , and the layer shows an abrasion wear with Wyzenbeek grain 40 of no more than 50 micrometers per 1000 cycles.

3. The composite sheet according to claim 2, characterized in that the stretching capacity of the composite sheet and the capacity of compression of the hair-like layer impregnated with resin are, each, no greater than 10%.

4. The composite sheet according to claims 1, 2 or 3, characterized in that the groups of hair-like fibers are in the form of inverted U-shaped curls or vertical yarns having an average separation in the range of 0.1 to 2 mm, and a ratio of height to basis in average curl of at least 0.5, the curls are formed by twisted yarns and the flat fibrous web is provided at least in part by contracted yarns.

5. The composite sheet according to claim 4, characterized in that the flat fibrous web is a woven or knitted fabric comprising a combination yarn having a contracted core and a twisted hard yarn wrap, the twisted wrap forms groups of fibers similar to hairs

6. The composite sheet according to claim 4, characterized in that the flat fibrous web is a woven fabric formed with at least two bars, a bar provides a combination yarn with a core contracted, and a second bar provides a hard thread which is twisted to form hair-like groups.

7. The composite sheet according to claim 4, characterized in that the flat fibrous layer comprises a non-woven fabric or textile decitex fibers or filaments and the hair-like fiber groups are flocked yarns.

8. The composite sheet according to claim 4, characterized in that the flat fibrous layer comprises a contracted woven fabric and the groups of hair-like fibers are flocked yarns.

9. The composite sheet according to claim 4, characterized in that the U-shaped curls are formed in part from a nonwoven layer contracted from fibers substantially not bound textile decitex.

10. The composite sheet according to claim 4, characterized in that the flat fibrous layer is a fibrous layer joined by stitching, wherein the stitched yarn is a combination yarn having a shrinkable core and a hard yarn wrap which is wrapped loose or loose.

11. The composite sheet according to claim 4, characterized in that the flat fibrous layer and the groups of hair-like fibers are both provided, from a fibrous layer joined by stitches of two contracted bars, wherein the yarn joined by stitches of a bar it is a combination yarn with a core that can be contracted and the yarn attached by stitches of the second bar is a hard yarn.

12. The composite sheet according to claims 1, 2 or 3, characterized in that the hair fibers and the flat fibrous web are provided by a velor fabric.

13. A process for producing a composite abrasion-resistant sheet, characterized in that it comprises the steps of providing a fabric having a thickness of 0.5 to 3 mm within which groups of hair-like fibers are generally perpendicular to the surface of the fabric and they are present in an effective concentration of fibers and hairs of at least 0.1 g / cm 3, and groups of hair-like fibers are connected to, and protrude from, a flat fibrous network located on or on the surface of the cloth, e immobilize the groups of fibers similar to hairs in their perpendicular position when incorporating resin in the fabric in an amount that constitutes in the range of 30 to 90% of the total weight of the impregnated fabric and which provides the impregnated fabric with a total density in the range of 0.4 to 1.2 g / cm3, and a hairs parameter of at least 0.3 g / cm3.

14. The process according to claim 13, characterized in that the concentration of groups of hair-like fibers increases upon contracting the area of the fabric by a factor of at least 2.

15. The process according to claim 14, characterized in that the fabric shrinks by a factor in the range of 3 to 12.

16. The process according to claim 14 or 15, characterized in that the fabric is a woven fabric that is knitted with combination yarns under tension, and optionally, with hard yarns, the combination yarns have an elastic core combined with a filamentary wrap which form fabric stitches that provide intervals of at least 1 mm in length, and tension is released in the contraction stage.

17. The process according to claim 13, characterized in that the immobilization of the groups of hair-like fibers and the stabilization of the dimensions of the fabrics is carried out simultaneously by the incorporation of the resin.

18. The process according to claim 17, characterized in that the composite sheet is additionally stabilized by low tension joining elements to the rear part or support of the composite sheet.

19. A shaped article having at least a portion of the surface thereof a composite abrasion resistant sheet, according to claim 1.