NL8000868A - NON-WOVEN TEXTILE MATERIAL AND A METHOD FOR THE MANUFACTURE THEREOF. - Google Patents

Description

. 1 F. 0.28.746 -¾

With woven textile material and a method for its manufacture.

The invention relates to new and improved non-woven textile materials and methods for the manufacture thereof.

Non-woven textile materials have been known for some time.

5 Textile woven materials are made from synthetic fibers such as polyester fibers and polypropylene fibers. Generally, these textile materials are obtained by forming a web of fibers and by treating the web with a binder used as an adhesive to hold the fibers together and to provide strength. In some cases (e.g. the spinning bonding technique), synthetic polymers are extruded into filaments and formed directly into webs which are self-adhesive, yielding the textile material as the final product. In other instances, the fibrous web is liquidly rearranged and then a resin used as a binder is added to form an efficiently cohesive nonwoven fabric.

See, for example, U.S. Pat. Nos. 2,862,251) 5,055,721, 5,195,436, 3,769,659, 3,081,515, and 5-025,585. There are still other non-woven textiles obtained by forming a web of synthetic fibers, and by treating the web with high-pressure jets to entangle the fibers and to obtain a strong fabric that does not contain a binder required to be self-supporting and effective for many applications. Such a method is described in U.S. Patent 5,485 * 706 and Canadian Patent 791,925.

The known non-woven polyester fiber textile materials have the following drawbacks, inter alia: adhesion-bonded polyester textile fiber webs require relatively large amounts of adhesive binders to obtain a fabric of sufficient strength. The large amount of binder increases costs and can adversely affect the desired textile properties of the fiber itself. The product obtained by binding 55 spinning is expensive and since the product consists of continuously extruded filaments there are also limitations with regard to the functional properties and the 3000888 * * * 2 ..

orientation as a textile material. For example, spun-bonded fabrics in the region of relatively large weights of the products may be less flexible and stiff. The highly entangled fabrics of U.S. Patent 5,485-706 and Canadian Patent 791,925 have excellent fabric properties, but the process requires significant capital investment and large amounts of energy.

The invention provides a method and a fabric-like product in which the stated drawbacks do not occur.

The invention was based on the problem of providing a relatively economical process for obtaining strong durable: non-woven textile materials with a reduced binder content.

The invention was also based on the problem of providing a method for obtaining strong durable non-woven textile materials of polyester and / or polyolefin fibers.

The invention was also based on the problem of providing strong durable non-woven textile materials of polyester and / or polyolefin.

Previously, the invention was based on the problem of providing an economical process for obtaining strong durable non-woven polyester and / or polyolefin textile materials with a reduced binder content.

The invention provides a highly durable non-woven textile material consisting of a layer of polyester and / or polyolefin fibers arranged in a regularly repeating pattern of weakly entangled fiber portions with a density per surface. greater than the average density of the remainder of the layer and interconnecting fibers extending between the said portions and randomly weakly entangled in the said portions and a binder used in the said layer as an adhesive is divided. These textile materials are obtained by a method comprising the steps of a weak entanglement of a layer of polyester and / or poly-55 olefin fibers followed by the application of the adhesive used for the binding to the weakly entangled layer.

The non-woven textile material according to the invention consists of a layer of polyester and / or polyolefin fibers, the fibers of which are arranged in a regularly repeating pattern of weakly entangled fiber parts with a density per 8 0 0 0 8 8 8 surface -¾ rubber that is greater than the average density of the rest of the layer. The fiber layer contains interconnecting fibers that extend between the said weakly entangled fiber portions.

The interconnecting fibers are randomly entangled with each other in the sections. The textile material also contains an effective amount, for example about 2.5 to about 50% by weight of a binder used as an adhesive, based on the textile material and the binder. The binder used as an adhesive can be distributed in the textile material in a spaced pattern of intermittently applied amounts of binder or the binder can be homogeneously distributed throughout the textile material.

The non-woven textile material according to the invention is obtained by forming a layer of overlapping intersecting polyester and / or polyolefin fibers. The fiber-containing layer is applied to a support provided with openings, arranged in a pattern. The layer is sprayed with a liquid for randomly entangling the layer in a pattern of high density portions interconnected by fibers extending between the portions. The layer of weakly entangled fibers is then treated with the binder used as an adhesive.

The fibrous web can be formed by any known method, for example by the method of laying using air or by carding. The web is then weakly entangled by passing the fibrous web under a substantially columnar flow of liquid, the web being supported by a perforating or patterning carrier. A device such as the device described in U.S. Pat. No. 3,485,706 can be used for entanglement. It is important for the invention that the fiber layer is weakly entangled. For example, it is preferred that the weakly entangled fiber layer have a fiber entanglement structural size of less than 0.1 (the method of determining the fiber entanglement structural size is described below).

A device which is particularly suitable for carrying out the method according to the invention is a device with a .a. unit fitted with rows of apertures through which a liquid (usually water) is injected under pressure in the form y | of mainly columnar rays. A suitable device 40 has 20-25 rows of apertures, the apertures being arranged in a number of ... 8 0 0 0 8 6 8-4 + about 12-20 per cm. The openings preferably have a round cross section with a diameter of 0.013 - 0.018 cm. The distance between the fibrous web and the openings under which the web is fed can be about 2.5-5.1 cm.

Appropriate process conditions are utilized using the stated device; a liquid pressure of about 14.1 to 49 at at and a velocity of the web of at most 91 44 44 m per minute 2 oor for a fibrous web with a weight per m of about 17 0 0 to 85.0 g. The appropriate process conditions are each determined on the basis of preliminary tests.

After the fibrous web is weakly entangled, the web is bonded in a conventional manner. For example, the weakly entangled web can be passed through a printing and binding device that works with a pair of counter-rotating rollers. The top roller (counter-presser) is adjustable and the bottom roller (applicator) is provided with a relief according to a pattern with which the fleece is to be printed. The bottom roll is partially immersed in a bath of a solution or a suspension of a binder. As the roller rotates, the roller takes an amount of the binder 20 on a scraper blade that strokes the roller while the amount of binder present in the relief is not stripped off. As the web passes through the gap between the rollers, the amount of binder from the relief of the respective cartridge is pressed onto the web. This method is generally known. This method of simultaneously bonding nonwoven fibrous webs is described in U.S. Pat. Nos. 2,705,498, 2,705,687, 2,705,688, 2,880,111, and 3,009,822. If desired, the web can also be bonded under total saturation.

As the binder used as an adhesive, any water-containing latex binder can be used, which is usually used as a binder for non-woven textile material. Such binders include acrylic binders, ethylene-vinyl acetate copolymers, SBR latex rubbers, and the like.

After the binder has been applied, the pressure-treated fleece is dried in the usual manner, for example by passing the fleece over a number of drying cans.

The binder is used in an effective amount, that is, an amount that yields textile material of sufficient strength and consistency for the final application. The exact amount of the binder used is partial g fs Π fj § ?? g.

Depending on factors such as the nature of the fiber material, the weight of the fibrous layer, the nature of the "binder, and the like. In general, an amount of from about 5 to about 30% by weight" is based on the weight. of the fibers and the binder, efficiently.

The fibers used to obtain the products according to the invention are polyester or polyolefin fibers, such as polypropylene fibers or high-density polyethylene fibers. It may be fibers of denier or more, and may be short fibers of 6.4 mm in length, as well as fibers in the form of infinite filaments. Preferably fibers with a length of 19.2 to 50.8 mm 2 are used. The weight per m of the fiber layer for obtaining the textile material according to the invention can vary between 4 and 76 g and a few tens of grams.

The invention is illustrated by the following examples. Example I

A nonwoven fabric of 1.75 denier polyester fibers 2 in length of 3> 81 cm with a weight per m of 25.69 g was produced by the air-laying method using a device with the nickname "Rando Webber ", a device marketed by Rando Machine Corporation of Rochester of Hew York. The web was placed on a woven tape. The tape was obtained by weaving 8 warp threads and 10 weft threads per cm. The band had 82 openings per cm. The web and tape were passed under 16 dividers. Each manifold had two rows of 5 apertures per cm and was moved transversely to the web. Each opening was rectangular in shape with dimensions of 0.03 x 0.04 cm. Water was sprayed through the openings at a pressure of about 17.58 ounces onto the web, weakly entangling the fibers in a pattern of high density sections. The weakly entangled fleece was passed through a pair of pressure rollers. The top roller was a flannel-lined rubber counter-pressure roller, and the bottom roller was an embossed roller. The relief of the roll consisted of two wavy lines per cm parallel to the roll axis (see Figure 1 of U.S. Pat. No. 3,009,822). Each line had a width of about 0.06 cm. The roller rotated in a container containing a binder and received an amount of the binder and applied this amount to the web. The binder was formulated in the following manner: a self-crosslinking vinyl acrylic terpolymer HS2853> a product sold by Rational Starch Company 8000868 6 ¥ * product; water; and a water-soluble hydrophilic surfactant with the trade name Tween 20, a product of Atlas Chemicals.

2

The binder was applied in an amount of about 5> 98 g per m. The resulting textile material was dried at a temperature of 132 ° C for 1 minute to remove excess water and to cure the binder. textile material contained weakly entangled fiber sections of greater density. The higher density sections were interconnected by fibers extending between them. The material of the binder was applied transversely of the textile material and bonded the fibers together. of the obtained textile material was tested using an Instron tensile strength determination apparatus according to the ASTM D 1117 method. The textile material had a peel strength in the machining direction of 0.053 kg / cm / g and a peel strength in the transverse direction of 0.04 kg / cm / g.

Yergeli. Example 1

For comparison, a portion of the polyester fiber air-woven web of Example I was not weakly entangled; the air-woven web method was treated with the binder and cured under conditions which corresponded with that of Example 1. Also, an additional amount of the polyester fiber fleece obtained by the air-laying method as in Example 1 was weakly entangled and then dried to remove the water. No binder was used. The two samples for comparison were tested for peel strength according to the method described in Example I. The textile material which was bonded only with the binder used as an adhesive and was not weakly entangled had a machining peel strength of 0.025 kg / cm / g and a transverse peel strength of 0.009 kg / cm / g. The fabric that was weakly entangled, but not bound by the adhesive binder, had a machining peel strength of 0.021 kg / cm / g and a transverse peel strength of 0.016 kg / cm / g.

Example II

According to methods analogous to the procedures described in Example I and in Comparative Example I, polypropylene-40 fibers were fabricated using the air-laying method using 8000888 7% of the "Bando Webber" device, and the webs were then subjected to a weak entanglement combined with a feed with NS2853 (Test No. 1), only a weak entanglement (Test No. 2), and only a bond under pressure with HS2853 (Test No. 3). non-woven textiles were tested on the gripping strength and specific gripping strength (ASTM D 1117) in the machining direction and in the transverse direction. The results are shown in Table A. .

TABLE · A

10 Test Weight in Gripping Strength Specific gripping strength 2/2 no.g / m in kg / cm in kg / cm / g / mm / do / dm / dc / d 1 28.66 1.987 1.557 9.957 7.815 2 20.74 0.107 0.090 0.803 0.642 15 3 28.22 0.465 0.286 2.355 1.445

Comparative example 2

According to a method analogous to the methods described in Example I and Comparative Example 1, rayon fibers were processed into a web using the air-laying method using the "Rando Webber" device and then subjected to a weak entanglement combined with a bond under pressure with NS2853 (Test No. 1), only a weak entanglement (Test No. 2) and only a bond under pressure (Test No. 3). The resulting nonwoven textiles were tested for peel strength (ASTM D 1117) in the machining and transverse directions. The results obtained are shown in Table B.

TABLE · B

/ 2 p

Test No. Weight in g / m Af tensile strength in kg / om / g / in

30 M / D C / D

1 33.46 0.051 0.029 2 24.67 0.045 0.028 3 32.45 0.056 0.036

In contrast to the case of the polyester scythe and the 35% lypropylene fibers, the strength values obtained in rayon fibers that were weakly entangled and bound under pressure were not greater than the sum of the values of the strengths obtained by only weak entanglement and only binding under pressure. It was found that printing without weak entanglement yielded greater values of strength than printing combined with weak entanglement.

Example III

A 1.5 denier polyester fiber web 2 of 4> 45 cm in weight per m of 18.0 g was made using the "Rando Weber" device. The web was placed on a 16x14 woven tape. The web and tape were passed under four strips each having 20 apertures per cm and moved transversely. The openings were round in shape with a diameter of 0.013 cm. Water at a temperature of 60 DEG C. was sprayed through the openings at a pressure of 35> 2 at the web to weakly entangle the fibers in a pattern of high density sections. The speed at which the belt and web were moved under the openings was 13 73 m / min. The weakly entangled fleece was dried by passing the fleece 15 over a number of steam cans.

Portions of the weakly entangled web were bound under saturation by sloshing with varying amounts of a self-crosslinking vinyl acrylic terpolymer latex NS2853> a commercial product from National Starch Company. The binder 20 containing samples were dried at 149 ° C. The non-bonded and bonded webs were tested for the specific grip tensile strength and peel strength. The results are shown in Table C. Comparative example 3

Using the polyester fibers described in Example III, according to the procedure of US Pat. Nos. 2,862,251 and 3,055 * 721 using the device "Rando

Webber "made a" rose bud "fleece. Water pressure 2 used was 14 * 1 at. The fleece-like product had a weight per m of 19.2 g. The fleece was dried and then portions thereof were mixed with different amounts of the Example 3 described binder bonded under saturation and dried at 149 ° C. Unbound and the bonded webs were tested for the specific gripping strength and peel strength The results are reported in Table C.

8000 868 9 '

TABLE C

Binder content Specific grip tensile strength in kg / cm / g / m in wt. 6 example III comparative example 5

M ^ D C / ü M / D C / D

o 8.672 5.942 0.642 0.589 2.5 14.614 12.653 10.492 6.745 5 17.290 13.650 10.974 9.368 10 19.324 16.380 15.899 16.005 20 16.113 12.901 18.623 17.665 40 18.040 12.365 15.578 15.203 2 _ Tensile strength in kg / cm / g / m_ example III comparative example 5 m / dc / dc / d 0 0.021 0.009 0.002 0.001 2.5 0.056 0.030 0.018 0.012 5 0.061 0.042 0.031 0.028 10 0.085 0.052 0.059 0.054 20 0.125 0.049 0.080 0.084 40 0.108 0.045 0.083 0.082

From the results with the samples mentioned, it can be seen that the sample of Example III containing 2.5% by weight of binder had sufficient processing strength and could be used as an intermediate material for the manufacture of clothing. Comparative Example 3 containing 2.5 wt.% Binder had a strength just sufficient for its processing, had very poor abrasion resistance and had very poor surface bond strength of the fibers and was found to be cohesive which was insufficient for commercial application. Comparative Example 10 may not have sufficient consistency for commercial use up to a binder content of 10 wt%; however, at a binder content of 10% by weight, the stiffness caused by the binder begins to cause a limitation of the potential for commercial use.

15 Structural measure of fiber entanglement

The unbound samples of Example III and Comparative Example 3 were tested for the "^" value, that is, the value of the structural measure of the fiber entanglement. The results were as follows: 8000868 10.

> example III 0.0564 comparative example 5 0.0190.

The method for determining this value was the following: Structurally, the degree of fiber entanglement is related to the concentration of the fibers in the entangled portion (C) and to the density of the entangled mass (d). The product of these two factors provides a measure of the frictional bonds the interaction of the fibers in the entangled portion, which serves to hold the fibers in the textile material in place, allowing the fiber strength to be maximized if the textile material is subject to a tax. Also influencing the maximum utilization of the fiber strength, the co-load under load has been developed by the group of fibers extending between any two entangled portions, the co-operation and the co-load. 15 the mean free length factor of the individual fibers in the group (F) are inversely proportional to each other. The structural measure of entanglement and the cooperation (s) is defined by the following equation s S =.

S again relates to the percentage of fiber strength converted to textile material strength. This relationship can be approximated by the following empirical equation: S = 0.0593 + 0.00562 (£ conversion) + 0.000543 (% conversion).

The fiber concentration factor (c) corresponds to the ratio of the fiber length in the entangled portion to the length that would be present if the fibers were not patterned and / or entangled, ie if the fibers of the textile material are uniformly distributed in the plane of the textile material. Since there is a direct relationship between fiber length and fiber weight, the factor of fiber concentration (C) can also be described by the ratio of the weight per unit area of the entangled portion (W ^) to the weight per area. unit of the total textile material (V2), that is, V1

35 ° = V

w2 and V2 are determined by direct measurement on the sample of the textile material. With respect to, an average of ten values is used and each value is determined by cutting 40 the entangled mass or a specific portion thereof from the 8000868 11 textile material with a suitable die. The area of the mass corresponds to the area of the mold. The ten samples are simultaneously weighed on a suitable micro-analytical scale.

The density (d) of the entangled mass can be determined by calculating the volumes of the listed cut samples. To this end, the samples are held axially on awl and photographed 20 times to obtain a cross-sectional view. The photographed cross-sectional view may be irregular in shape. In such a case, the irregular shape is approximately considered to consist of rectangles and / or triangles. The dimensions of the shapes are then measured and the corresponding volumes are calculated on the basis of geometric formulas. The total weight of the ten samples is divided by the total of the ten volumes, whereby the average density (d) in g / cm 2 of the entangled portion is obtained. The average free length factor (F) of the fibers in the group extending between two entangled portions is determined by direct observation (under a microscope) of the fibers in that group and by comparison with control material.

In practice, it has been observed that structures which have been modified. manufactured from straight (ie, not crimped or crimped) fibers do not have values of magnitude of one (corresponding to no curvature). Instead, some free length is always present and a suitable group value that can be considered for structures made of straight fibers is P = 1.4. Thus, it has been observed that the value of samples made from conventional staple fibers or weakly crimped filaments 30 ranges from 1.8 to 2.5. For such fibers, an average group value of F = 2.1 may be considered. The values of F measured in each case should be taken into account for strongly shrunk fibers. From the formula of S, it appears that the free length factor and the change in strength are inversely proportional to each other, i.e. the greater the free length factor, the poorer the fiber cohesion and the greater the reduction. the weight per unit area of the sample under load to tearing of the material.

8000858

Claims (10)

1. Strong, durable, non-woven textile material, characterized by a layer of polyester and / or polyolefin fibers, the fibers being arranged in a regularly repeating pattern of weakly entangled fiber sections with a density of those sections greater than the average density of the remainder of the layer, and with interconnecting fibers extending between the portions of the entangled fibers and randomly weakly entangled with each other in the said portions with an effective amount of a binder used as an adhesive. Textile material according to claim 1, characterized in that the fibers are polyester fibers. Textile material according to claim 1, characterized in that the fibers are polypropylene fibers. 4 · With woven textile material according to claim 1, 2 or 3> characterized in that the binder used as adhesive is uniformly distributed throughout the entire layer. Nonwoven textile material according to claim 1, 2 or 3, characterized in that the binder 20 used as adhesive is divided into a spaced pattern of intermittently applied amounts of the binder. 6. Process for the production of a strong, durable, non-woven textile material, characterized in that a) a layer of overlapping intersecting polyester fibers or polyolefin fibers or both fibers is formed, b) the layer is applied on a carrier, provided with openings c) directs a liquid in substantially columnar flowing jets onto the layer for arranging the fibers in a pattern of weakly entangled fiber portions and d) applies an adhesive used as an adhesive in an effective amount to the arranged layer. 7. A method according to claim 6, characterized in that a carrier with a predetermined topography is used as the carrier provided with openings. 8. Process according to claim 6 and / or 7, characterized in that water is used as the liquid. 9. A method according to claims 6-8, characterized in that the textile material is dried at an elevated temperature 40 to cure the binder used as adhesive. 3000368 13 V * · * v * 10. A method according to claims 6-9f, characterized in that as a carrier provided with openings a carrier with a predetermined topography is used, that water is used as the liquid and that the textile material is dried at an elevated temperature to cure the material. binder used as adhesive. 8000868