Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
  • Y10T428/2495—Thickness [relative or absolute]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
  • Y10T428/269—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension including synthetic resin or polymer layer or component
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
  • Y10T442/273—Coating or impregnation provides wear or abrasion resistance

Definitions

• Another expedient is to dispose fibers of smaller size, that is finder in cross-section, at the surface of the fabric as compared to the size of the fibers within the body of the fabric. With this system there is an excessive tendency of the fine fibers to break and become lost.
• non-woven fabrics of resilient character but having improved surface characteristics including a softer hand and freedom from pilling are obtained by the application of a thin surface layer of cellulose fibers to one or both surfaces of the main body of the non-woven fabric formed of synthetic hydrophobic fibers of high modulus of resilience, applying a binder in the form of an aqueous polymer dispersion removing excess binder, and then drying and heating the impregnated web or fabric to convert the binder to insoluble and infusible form.
• the invention is applicable to non-woven webs of such synthetic hydrophobic fibers as nylon, saran, polyethylene glycol terephthalate, and acrylonitrile fibers including those of polyacrylonitrile and copolymers of 70% by weight or more of acrylonitrile with vinyl acetate, acrylic acid esters, vinyl pyridine, mixtures thereof, and so on.
• the non-woven web of such fibers may be formed by a card or on a so-called Random Webber or by deposition from an air stream carrying the fibers.
• the web of main fibers is at least mil in thickness and preferably is from 2 to 1,000 mils in thickness:
• the fibers should have at least a textile-making length, by which is meant that the length is at least /2 inch and may be longer to facilitate handling on the equipment used for forming the web as in the case of a card hereinabove.
• the denier of the hydrophobic synthetic fibers may be from 1 to 20 and is preferably from 2 to 5.
• the cellulose fibers may be of cotton or any type of regenerated cellulose rayon and they may have deniers from 1 to 10 and up.
• the cellulose fibers may be formed separately into a web that is then superimposed upon the Web of hydrophobic fibers. Its web thickness may be 3,Z3,847 Patented Aug. 31, 1965 from A to 2 mils as a minimum. The minimum thickness is such as to provide a complete covering of the surface of the hydrophobic fiber web to which the cellulose web is applied, which covering is at least one fiber in thickness.
• the working examples show covering cellulosic webs having weights in the range of about onehalf to three-fourths ounce per square yard.
• the cellulose fiber web may be formed separately on the same type of equipment as the hydrophobic fiber web, after which one or more webs of the cellulose fiber is applied to the surface of one or more superimposed webs of the resilient fiber. If desired the cellulose fiber webs may be applied to both surfaces of the hydrophobic fiber web.
• the hydrophobic fiber web may be placed on or passed continuously under or over a suction box or screen either above or beneath a duct for directing a cellulosefiber air stream against one surface of the hydrophobic fiber web to deposit the cellulose fibers thereon.
• the time during which the hydrophobic fiber web is held in stationary position is controlled to provide the desired thickness of cellulose fiber deposit.
• the time of passage of the hydrophobic fiber web over or under the suction box is predetermined to provide the desired thickness of cellulosic fiber deposit.
• the assembled web is treated with a suitable aqueous dispersion of a binder.
• the binder is of a type which is capable of forming a bonded web which is resistant to laundering as well as drycleaning.
• binders include copolymers containing from 0.5 to 20% by weight of units containing such functional groups as glycidyl, carboxyl (in free-acid or salt form), amide, amine, hydroxyl, and so on.
• Specific compounds that serve as monomers for the preparation of such copolymers include glycidyl methacrylate, acrylic acid, methacrylic acid, itaconic acid, acrylamide, dimethylaminoethyl methacrylate, and fl-hydroxypropyl methacrylate.
• These functional monomers may be copolymerized with other monoethylenically unsaturated comonomers provided that they are of such character as to produce copolymers of Water-insoluble character.
• Examples of such comonomers include esters of acrylic acid with saturated aliphatic alcohols having 1 to 18 carbon atoms, esters of methacrylic acid with saturated aliphatic alcohols having 1 to 18 carbon atoms, acrylonitrile, methacrylonitrile, styrene, vinyltoluene, vinyl acetate, vinyl chloride and vinylidene chloride.
• Preferred copolymers which assure the production of a soft hand in the fabric are those which have a T value not over 20 C. Where stiff hands are permissible the copolymers may, of course, have higher T, values.
• the T value referred to is the apparent second-order transition temperature or inflection temperature which is found by plotting the modulus of rigidity against temperature. A convenient method for determining modulus of rigidity and transition temperature is described by l. Williamson, British Plastics 23, 87-90, 102 (September 1950). The T value here used is that determined at 300 kg./cm.
• aminoplast examples include the water-soluble condensates of formaldehyde with urea, N,N-ethyleneurea, and aminotriazines such as melamine or dialkyl-substituted melamines, as well as the water-soluble alkylated methylol condensates obtained from such alcohols as methanol, ethanol and isopropanol.
• polyepoxides examples include those of copending application for US. Serial No. 727,245, filed April 9, 1958, now US. Patent 3,015,595, and they are incorporated herein by reference.
• the excess is removed by squeezing and the impregnated web is then dried and the binder cured by heating to a temperature of about 105 C. up to 300 C. for a time ranging from about one-half minute to ten minutes, the shorter time being applied with the higher temperatures.
• the temperature in all cases should not be such as to cause the fabric to be damaged.
• the impregnation with the binder may be effected by spraying, by immersion, and by rolls.
• any suitable textile equipment such as a textile pad may be employed for this purpose.
• the concentration of the binder dispersion and the extent of squeezing should be controlled to provide the application of to 150% by weight, and preferably about 20 to 40% by weight, of a dry binder based on the weight of dry fiber.
• the bonded non-woven fabrics of the present invention are characterized by outstanding resilience and bulkiness in conjunction with freedom from pilling and improved hand. They are highly porous and adapted to be washed and drycleaned repeatedly. On this account they are well adapted for garment usage and because of their freedom from pilling and their desirable feel they present excellent appearance even after being washed and drycleaned.
• the non-woven fabrics of the present invention may also be used as absorbent materials such as wiping cloths, bibs, diapers or diaper fillers, table cloths and doilies. They are also useful as filters, decorative sound insulation panels, garment fillers, and heat insulation fillers.
• the non-woven fabrics of the present invention may also form one component of a laminar article.
• this embodiment it is frequently desirable to employ the embodiment in which only one surface is covered with cellulose fibers. Then the cellulose fiber layer is exposed and the opposite surface of the hydrocarbon fiber is adhered to a film or sheet of other material.
• Such other material may be simply a thin film of polyethylene, a sheet of cellophane, a foamed or spongiform polyurethane or polystyrene.
• the other laminar material may be a layer of paper, a veneer of wood, or a plastic film.
• Example 1 (a) A randomly laid web of nylon fibers weighing about 2.0 oz./yd. was sandwiched between two random laid webs of cotton fibers, each of which weighed about 0.75 oz./yd. This assembly was then saturated with an aqueous binder dispersion consisting of the following:
• the resulting fabric was then given ten automatic home launderings. No pilling of this fabric occurred.
• part (b) The procedure of part (a) was followed except that the nylon web was not faced with the cotton webs. When this fabric was laundered as in part (a) numerous pills developed.
• Example 2 (a) A randomly laid web of polyethylene glycol terephthalate fibers weighing about 2.5 oz./yd. was sandwiched between two parallel laid webs of viscose rayon fibers, each of which weighed about 0.5 oz./yd. This assembly was then saturated with an aqueous binder dispersion consisting of the following 350 parts of a copolymer of parts of ethyl acrylate and 5 parts of N-methylolacrylamide.
• the resulting fabric was then given ten automatic home launderings. No pilling of this fabric occurred.
• part (b) The procedure of part (a) was followed except that the polyethylene glycol terephthalate web was not faced with viscose webs. When this fabric was laundered as in part (a) numerous pills developed.
• Example 3 The web was squeezed between rubber rollers to provide a wet pickup of about percent and heated to 150 C. for 15 minutes to effect drying and curing.
• Example 4 A carded web of cellulose acetate fibers weighing about 3.0 oz./yd. was sandwiched between one carded web of cotton fibers weighing about 0.75 oz./yd. and a carded web of cuprammonium cellulose fibers weighing 0.5 oz./yd. This assembly was then saturated with an aqueous binder dispersion consisting of the following:
• a non-woven fibrous fabric comprising a main body of synthetic hydrophobic fibers having a thickness of at least A mil and having at least one surface thereof covered with a non'lwoven web of cellulose fibers having a weight in the range of about one-half to three-fourths ounce per square yard, fibers in the fabric being bonded by impregnation with a thermosettable binder comprising a copoly-rner containing functional groups by the reaction of which the bonded non-woven fabric has been converted to a condition in which it is resistant to laundering and drycleaning.
• a non-woven fabric formed of resilient synthetic hydrophobic fibers and cellulose fibers, a thin layer of cellulose fibers having a weight in the range of about one-half to three-fourths ounce per square yard being disposed on at least one face of the fabric and covering the hydrophobic fibers which.
• the main body of the fabric which has a thickness of at least V4 mil, fibers in the fabric being bonded by impregnation with S to 150% by weight, based on the dry weight of the fibers, of a therrnosettable binder comprising a copolymer containing functional groups by the reaction of which the bonded non-woven fabric has been.
• a non-woven fabric formed of resilient synthetic hydrophobic fibers and cellulose fibers, a thin layer of cellulose fibers having a weight in the range of about one-half to three-fourths ounce per square yard being disposed on at least one face of the fabric and covering the hydrophobic fibers which form the main body of the fabric having a thickness of at least V4 mil, fibers in the fabric being bonded by impregnation with 5 to 150% by weight, based on the dry weight of the fibers, of a thennosettable binder comprising a copolymer, with an apparent second order transition temperature not over 20 C., of monoethylenically unsaturated molecules comprising 0.5 to 20% by weight, based on the total weight of the molecules, of molecules containing functional groups by the reaction of which the bonded nonwoven fabric has been converted toa condition in which it is resistant to laundering and dryclean- 4.
• a non-woven fabric formed of resilient synthetic hydrophobic fibers and cellulose fibers, a thin layer of cellulose fibers being disposed on at least one face of the fabric and covering the hydrophobic fibers which form the main body of the fabric, fibers in the fabric being bonded by impregnation with 5 to 150% by weight, based on the dry weight of the fibers, of a thermoeettable binder comprising a copolymer, with an apparent second order transition temperature not over 20' C., of monoethylenically unsaturated molecules comprising 0.5 to 20% by weight, based on the total weight of the molecules, of molecules containing functional groups by the reaction of which the bonded nonwoven fabric has been converted to a condition in which it is resistant to laundering and drycleaning, the thickness of the layer of cellulose fibers being about V4 to 2 mils and sufficient to provide a complete covering of the main body of hydrophobic fibers being A mil to 1000 mils.
• a laminar article comprising a non-woven fabric adhered to a layerof other material, the fabric being formed of resilient synthetic hydrophobic fibers and cellulose fibers, a thin layer of cellulose fibers having a weight in the range of aboutone-half'to three-fourths ounce per square yard being disposed on at leastone face of the fabric and covering the hydrophobic fibers which form the main body of the fabric having a thickness of at least mil, fibers in the fabric being bonded by impregnation with 5 to by weight, based on the dry weight of the fibers, of a therrnosettable binder comprising a copolymer, with an apparent second order transition temperature not over 20' C., of monoethylenically unsaturated molecules comprising 0.5 to 20% by weight, based on the total weight of the molecules, of molecules containing functional groups by the reaction of which the bonded non-woven fabric has been converted to a condition in which it is resistant to laundering and drycleaning, the exposed face of the non-woven fabric being that
• a non-woven fabric formed of resilient synthetic hydrophobic fibers and cellulose fibers, a thin layer of cellulose fibers being disposed on at least one face of the fabric and covering the hydrophobic fibers which form the main body of the fabric, fibers in the fabric being bonded by impregnation with 5 to 150% by weight, based on the dry weight of the fibers, of a thermosettable binder comprising a copoiymer, with an apparent-second order transition temperature not over 20' 0., of monoethylenically unsaturated'molecules comprising 0.5 to 20% by weight, based on the total weight of the molecules, of.
• the thickness of the layer of cellulose fibers being about V4 to 2 mils and sufiicient to provide a complete covering of the adjacent hydrophobic fibers, and the thickness of the main body of hydrophobic fibers being V4 mil to 1000 mils, the weight of hydrophobic fibers predominating over that of the cellulose fibers in the fabric.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Nonwoven Fabrics (AREA)

Priority Applications (5)

Applications Claiming Priority (1)

Publications (1)

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Family Applications (1)

Country Status (5)

Cited By (2)

Families Citing this family (2)

Citations (2)

• 0
  • BE BE625497D patent/BE625497A/xx unknown
  • NL NL285726D patent/NL285726A/xx unknown
• 1961
  • 1961-11-29 US US15585061 patent/US3203847A/en not_active Expired - Lifetime
• 1962
  • 1962-11-06 GB GB4191862A patent/GB1008283A/en not_active Expired
  • 1962-11-29 FR FR917057A patent/FR1340028A/fr not_active Expired

Patent Citations (2)

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