US3321356A - Production of flexible sheet materials - Google Patents
Production of flexible sheet materials Download PDFInfo
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- US3321356A US3321356A US381876A US38187664A US3321356A US 3321356 A US3321356 A US 3321356A US 381876 A US381876 A US 381876A US 38187664 A US38187664 A US 38187664A US 3321356 A US3321356 A US 3321356A
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- binder
- layer
- solution
- flexible sheet
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- 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
- D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/488—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
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- 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
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
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- 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
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/4334—Polyamides
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- 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
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
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- 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
- D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/498—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
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- 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
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- 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
- D04H1/645—Impregnation followed by a solidification process
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- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/009—Condensation or reaction polymers
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- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
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- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
- D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
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- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
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- 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
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N3/10—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with styrene-butadiene copolymerisation products or other synthetic rubbers or elastomers except polyurethanes
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
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- 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
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/904—Artificial leather
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- 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
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249933—Fiber embedded in or on the surface of a natural or synthetic rubber matrix
- Y10T428/249934—Fibers are aligned substantially parallel
- Y10T428/249935—Fiber is nonlinear [e.g., crimped, sinusoidal, etc.]
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- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/666—Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
- Y10T442/667—Needled
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- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/668—Separate nonwoven fabric layers comprise chemically different strand or fiber material
Definitions
- This invention relates to the production of flexible sheet materials comprising fibrous material and a flexible binder, including sheet materials intended to form a substitute for natural leather, and also sheet materials intended for the manufacture of belting, diaphragms, filters, and so forth. It is an object of the present invention to provide for differential distribution of the binder in the transverse sense, i.e. to enable the concentration of binder to be made greater at and near one surface of the material than it is at and near the other surface.
- a method of producing flexible sheet material comprises preparing a layer of fibrous material, applying to the layer a liquid comprising a binder and a vaporisable vehicle, and securing diflerential distribution of binder by applying heat to one surface of the layer differentially with respect to the other surface, removal of the vehicle by vapon'sation and (if appropriate) heat-curing of the binder being also effected by the application of heat.
- the differential heating just specified has been found to induce migration of binder away from the relatively cool surface and towards the relatively hot surface, and it is believed that this migration may result from a progressive rinsing of the binder from one surface to the other by the liquid phase of the vehicle, some of which is assumed to condense towards the relatively cool surface after being vaporised towards the relatively hot surface.
- the layer of fibrous mate rial, with the liquid comprising the binder and vaporisable vehicle should be confined and compressed between metal or other plates (or belts, if production is to be continuous) while the differential heating is performed.
- the differential heating may if necessary be supplemented by substantially uniform heating of the material under treatment when once the differential distribution of the binder has been provided for.
- Spacers may be used between the plates (or belts) to prevent excessive compression of the material under treatment, and also the edges of the plates (or belts) may be enclosed with a view to preventing excessively rapid escape of the vaporisable vehicle.
- the temperature of the hotter plate (or belt) in the differential heating should be high enough to vaporise this vehicle; the hotter plate (or belt) in the differential heating may also supply all the heat needed for any heat-curing of the binder, so as to avoid supplementary heating.
- the liquid comprising a binder and a vaporisable vehicle may be a solution, e.g. a solution of a polyurethane rubber or intermediate chemical system reacting to form such a rubber in acetone or another organic solvent, or a dispersion, e.g. a rubber latex or an aqueous emulsion of a solution of an elastomer in an organic solvent.
- a solution e.g. a solution of a polyurethane rubber or intermediate chemical system reacting to form such a rubber in acetone or another organic solvent
- a dispersion e.g. a rubber latex or an aqueous emulsion of a solution of an elastomer in an organic solvent.
- a supplementary binder e.g. a compounded rubber latex
- a supplementary binder e.g. a compounded rubber latex
- surface finishing coating e.g. of a polyurethane lacquer
- the layer of fibrous material used may take any of a variety of forms. It may for instance be in the nature of a felt, or a fleece.
- a specific example of the fibrous material layers which may be used is that comprising a web of interpenetrated crimped continuous nylon monofilaments which after needle-punching has been overlaid with a fleece of polypropylene staple fibres, the latter having been needle-punched beforehand and also after being laid on the nylon web.
- Particularly good results are obtainable if the binder-rich part of the product is derived from fine-denier fibres, egg. by laying one or more fine-denier fleeces on a coarser base web and if desired uniting them by needle-punching. This assists the migration of the binder and promotes continuity and fine poros ity in the binder-rich surface.
- the differential-heating technique of the present invention it is possible to obtain flexible sheet materials having a smooth, cfinely porous surface of binder on one side and a surface with much less or no binder on the other side.
- the present technique has (in the field for which it is intended) substantial advantages over the other techniques for differentially distributing the binder which we have considered; these other techniques were (1) surface application of binder, which was liable to give a rough surface or alternatively a readily detached non-porous stratum, (2) surface accumulation by pressing, which was liable to give undifferentiated ob verse and reverse surfaces, (3) gravitation to a lowermost surface, which was liable to give a non-porous surface layer and which in any case required an open fibrous layer and a high proportion of binder, and (4) capillary migration, which was liable to give a rough and uneven surface.
- FIGURE 1 is a cross-sectional view of a mat of fibres prior to impregnation with a binder
- FIGURE 2 is a cross-sectional view of the' mat subsequent to impregnation with a binder and after differential distribution of the binder;
- FIGURE 2A is an enlarged view of the uppermost layer of the mat shown in FIGURE 2;
- FIGURE 3 is a cross-sectional view of the mat subsequent to impregnation with a second binder.
- FIGURE 1 shows a cross-section through a mat 1 formed from a layer of crimped continuous nylon filaments 2 and a layer of polypropylene staple fibres 3.
- the mat 1 is made by laying a needle-punched mat of the staple fibres 3 on the layer of continuous filaments 2 and needlingthe assembled layers together.
- FIGURE 2 shows a cross-section through the mat after the mat has been impregnated with a polyurethane binder composition 5, and after differential distribution of this binder composition.
- the polypropylene staple fibre layer contains the major proportion of the binder composition and the layer of staple fibres and binder is shown by the reference numeral 4 in FIGURE 2.
- the polypropylene fibres 3 are embedded in the binder 5 as shown in the enlarged cross-section through the layer 4 in FIGURE 2A.
- the layer 4 also contains small air-spaces 6.
- the mat shown in FIGURE 3 contains a rubber composition (second binder composition) 7 which is applied to the mat shown in FIGURES 2 and 2A and is then cured. As shown in FIGURE 3, the rubber composition 7 penetrates the polyurethane layer 4 and fills the airspaces 6 of this layer.
- second binder composition second binder composition
- Example I A web of crimped continuous 6-denier nylon 66 monofilaments, laid under light tension in the form of parallel continuous yarns and subsequently relaxed, and which weighed approximately 20 grams per sq. ft. in the relaxed condition, was passed once through a needle-punching machine and then covered with a fleece of randomly oriented 3-denier polypropylene fibre of 2 /2" staple length which had previously been needle-punched and weighed approximately 6 grams per sq. ft. The assembly was then needled a further 4 times. A one foot square of the resulting composite felt weighing 24 grams was laid, nylon side downwards, on a steel plate covered With a polyethylene foil.
- the top surface was immediately covered with a sheet of polyethylene foil and then another steel plate.
- the assembly was placed in a cold platen press and compressed without spacers under a pressure of 230 lbs.-/ sq. in. for 75 seconds to distribute the solution uniformly. About 10 grams of the solution extruded at the edges and was not recovered. The press was then opened and the felt removed. At this stage it was a completely wetted open structure about 4 mm. thick. It was immediately laid, polypropylene fibre side upwards, between two polypropylene sheets and placed in a mould fitted with spacers to give a depth of 1 /2 mm. between the polypropylene sheets.
- This assembly was placed in a press having the bottom platen at room temperature and the top platen at 100 C., and pressed to 230 lbs/sq. in. After ten minutes the temperature of both platens was raised to 110 C. and pressing continued at this temperature for a further ten minutes. The press was then cooled and opened and the product removed. It consisted of a 2 mm. thick sheet having a supple feel and a smooth finely porous top surface consisting of compacted polypropylene fibres embedded in porous elastomeric polyurethane, the reverse (nylon fibre) surface of the sheet being denuded of polyurethane.
- This product had a tensile strength of 750 lbs./sq. in. and an elongation at break figure of 85%.
- a very leather-like product was obtained having a tensile strength of over 2000 lbs./sq. in., an elongation at break figure of over 80%, a flex life greater than 1 million cycles on the standard (SATRA) vamp-flexing machine, and a water-vapour permeability of 0.43 mg./sq. cm./hr. It conformed also with other typical natural leather test specifications.
- Example 11 The procedure of Example I was repeated except that the composite web employed consisted of grams per sq. ft. of continuous nylon 66, 5 grams per sq. ft. of 3-denier polypropylene staple and a top layer of 5 grams per sq. ft. of lVz-denier nylon 66 staple.
- Example II The product was very similar to that of Example I and after impregnation and coating had a flex life of over 3.8 million cycles.
- Example III A felt was prepared, impregnated and pressed exactly as in Example II except that the spacers were adjusted to compress the product to 1.0 mm.
- the top surface of the product was of the same character as before, but the back surface, although of an open fibrous texture, retained sufficient polyurethane for the material to serve as an artificial leather without any further impregnation treatment.
- Example IV The procedure of Example I was repeated exactly except that the random fleece of polypropylene was replaced by two laps of PAM-denier, high-crimp, 1 /2"-staple nylon 66, each weighing 3.5 grams/sq. ft. The first of these laps was laid with its principal fibre direction crossing the underlying nylon yarns at an angle of 45 and the second was laid at to the first, i.e. also crossing the underlying yarns at 45 but inclined in the opposite direction.
- Example V A web was prepared as in Example I and laid as before on a steel plate covered with a polyethylene foil. 60 grams of a freshly prepared compounded ammonia-preserved natural rubber latex mix of the following composition was poured centrally on to the top of the felt:
- Natural rubber latex (60% dry rubber content) 100.0
- Aqueous solution of potassium oleate (15 g./ g.
- Aqueous dispersion of sulphur 50 g./ 100 g. dispersion
- Aqueous dispersion of dibetanaphthyl-p-phenylene diamine 40 g./ 100 g. dispersion
- Aqueous dispersion of zinc diethyldithiocarbamate 5O g./100 g. dispersion
- Aqueous dispersion of zinc salt of mercaptobenzothiazole 50 g./ 100 g. dispersion
- 3.0 Water 54.0 Aqueous dispersion of zinc oxide 50 g./ 100 g.
- the latex mix soaked into the web and to some extent spread out.
- the top surface was immediately covered with a sheet of polyethylene foil and then another steel plate.
- the assembly was placed in the press and compressed without spacers at 230 lb./sq. in. for 30 seconds. About 15 grams of the latex mix extruded at the edges and was not recovered.
- the press was opened and the felt removed. At this stage it was a completely wetted, open structure about 4 mm. thick. It was immediately laid, polypropylene fibre side upwards, between two polypropylene sheets and placed in a mould fitted with spacers to give a depth of 1.5 mm.
- the assembly was pressed at 230 lb./sq. in. with the bottom platen initially att about 40 C. and the top platen at C. After 20 minutes the temperature of the bottom platen had gradually increased to about 80 C., the top platen temperature remaining at 130 C.
- the press was then cooled and opened, and the product removed. It consisted of a fully dried and cured 1.5 mm. thick sheet. It had an extremely supple feel and a smooth finely porous top surface consisting of polypropylene fibres embedded in a porous vulcanized latex rubber, the reverse (nylon fibre) surface of the sheet being denuded of rubber and having acquired an attractively smooth surface by heat setting in the presence of the steam from the latex evaporation. dicate sufliciently high-level properties to yield a good leather replacement material after a supplementary and more uniform impregnation with a further quantity of binder applied from the back.
- a web of the crimped continuous 6-denier nylon 66 monofil was relaxed as before and then needle-punched 6 times from alternate sides. It then weighed 19 grams per sq. ft.
- An emulsion of a liquid polyurethane rubber (Adiprene 11-100) was prepared as follows. 100 parts of Adiprene L-lOO were dissolved in 50 parts of toluene and then 4 parts of the addition product of ethylene oxide and nonylphenol sold under the trade name of Nonidet P-40 were stirred in.
- the following ingredients were mixed with 66 parts of water: 30 parts of a solution in 90 parts of water of 10 parts of sodium dodecyl sulphate, 20 parts of a solution in 95 parts of water of 5 parts of dioctyl sodium sulphosuccinate sold under the trade name Manoxol N, and 30 parts of an aqueous solution of ammonium caseinate made by dissolving in 990 parts of water 100 parts of lactic casein, 1 part of sodium pentachlorophenate and 9 parts of aqueous ammonia solution of specific gravity 0.880.
- the above Adiprene solution was slowly poured with high-speed stirring into the aqueous liquid, yielding an oil-in-water-type emulsion which remained colloidally stable for many weeks.
- the fieshly prepared emulsion was matured at room temperature for 24 hours by which time test films dried at room temperature on a glass plate consisted of coherent, substantially tack-free elastomer.
- the nylon web (1 sq. ft.) was treated with 50 grams of this matured emulsion and then given the same subsequent treatment as the web in Example V. (The extrusion loss in the first pressing was 14 grams of emulsion.)
- the product after the second pressing was a fully dried and cured 1.5 mm.-thick strong flexible sheet having a smooth finely porous top surface and a smooth open back surface devoid of Adiprene.
- Example VII A 1 ft. square nylon web similar to that in Example VI but weighing 23 grams was first impregnated substantially uniformly throughout its thickness with Adiprene binder by the following technique. 50 grams of a freshly prepared solution of 96 parts of Adiprene, 4 parts of trimethylolpropane and 1 part of stannous octoate, all dissolved in 400 parts of dry acetone, were poured on centrally, and the cold pressing applied as before. This caused the extrusion of 20 grams of the solution. On release, the remaining 30 grams of solution were found to be almost evenly distributed throughout the web. The web was immediately transferred to a well-ventilated hotair oven at 80 C.
- the final product was a leather-like sheet having a strongly increasing graduation of Adiprene binder content from the bottom to the top surface, and this top surface had the smooth and finely porous quality characteristic of the invention.
- a method of producing flexible sheet material which comprises distributing throughout a layer of fibrous material, a liquid comprising a binder for the fibres of said fibrous material and a vaporisable vehicle for said binder and applying heat to one surface of said layer to raise its temperature adjacent this surface above the tempera ture adjacent to the other surface to secure a differential distribution and a concentration of said binder adjacent said heated surface to remove the vehicle by vaporization and to heat-cure said binder.
- liquid comprising a binder and a vaporisable vehicle is a solution.
- liquid comprising a binder and a vaporisable vehicle is a rubber latex.
- the layer of fibrous material comprises a web of needle-punched interpenetrated crimp continuous nylon monofilaments overlaid with a fleece of needle-punched polypropylene staple fibres and needle-punched on the nylon web.
- a method according to claim 1 in which the liquid comprises a binder and a vaporisable vehicle is an aqueous emulsion of a solution of an elastomer in an organic solvent.
- Flexible sheet material which comprises a layer of matted fibrous material and a flexible binder for said fibres differentially distributed throughout said layer, the concentration of said binder being greater adjacent to one surface of said layer than adjacent the other surface of said layer.
- said layer of matted fibrous material comprises a layer of interpenetrated continuous monofilaments and a layer superposed on the above layer of randomly oriented fibres, and in which said concentration of binder is greatest in said superposed layer.
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- Engineering & Computer Science (AREA)
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- Chemical Kinetics & Catalysis (AREA)
- Mechanical Engineering (AREA)
- Dispersion Chemistry (AREA)
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- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
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- Nonwoven Fabrics (AREA)
Description
May 23, 1967 P. MERRIMAN ETAL 3,
PRODUCTION OF FLEXIBLE SHEET MATERIALS 7 Filed July 10, 1964 E m MMMW wflmR mawdfm Z 3. 5 M m 3 P. p Y B United States Patent 3,321,356 PRODUCTION OF FLEmLE SHEET MATERIALS Peter Merriman, Edgbaston, and Dennis Ivor Clarke, Birmingham, England, assignors to Dunlop Rubber Company Limited, London, England, a British company Filed July 10, 1964, Ser. No. 381,876 Claims priority, application Great Britain, July 31, 1963,
30,289/ 63 Claims. (Cl. 161-81) This invention relates to the production of flexible sheet materials comprising fibrous material and a flexible binder, including sheet materials intended to form a substitute for natural leather, and also sheet materials intended for the manufacture of belting, diaphragms, filters, and so forth. It is an object of the present invention to provide for differential distribution of the binder in the transverse sense, i.e. to enable the concentration of binder to be made greater at and near one surface of the material than it is at and near the other surface.
According to the present invention, a method of producing flexible sheet material comprises preparing a layer of fibrous material, applying to the layer a liquid comprising a binder and a vaporisable vehicle, and securing diflerential distribution of binder by applying heat to one surface of the layer differentially with respect to the other surface, removal of the vehicle by vapon'sation and (if appropriate) heat-curing of the binder being also effected by the application of heat. The differential heating just specified has been found to induce migration of binder away from the relatively cool surface and towards the relatively hot surface, and it is believed that this migration may result from a progressive rinsing of the binder from one surface to the other by the liquid phase of the vehicle, some of which is assumed to condense towards the relatively cool surface after being vaporised towards the relatively hot surface.
Normally it is desirable that the layer of fibrous mate rial, with the liquid comprising the binder and vaporisable vehicle, should be confined and compressed between metal or other plates (or belts, if production is to be continuous) while the differential heating is performed. Generally it is appropriate to heat positively one of the plates (or belts) and to leave the other unheated, or to apply positive cooling, though it should be understood that according to the nature of the binder used, the nature of the product desired, and so forth, the differential heating may if necessary be supplemented by substantially uniform heating of the material under treatment when once the differential distribution of the binder has been provided for. Spacers may be used between the plates (or belts) to prevent excessive compression of the material under treatment, and also the edges of the plates (or belts) may be enclosed with a view to preventing excessively rapid escape of the vaporisable vehicle. As will be appreciated, the temperature of the hotter plate (or belt) in the differential heating should be high enough to vaporise this vehicle; the hotter plate (or belt) in the differential heating may also supply all the heat needed for any heat-curing of the binder, so as to avoid supplementary heating.
The liquid comprising a binder and a vaporisable vehicle may be a solution, e.g. a solution of a polyurethane rubber or intermediate chemical system reacting to form such a rubber in acetone or another organic solvent, or a dispersion, e.g. a rubber latex or an aqueous emulsion of a solution of an elastomer in an organic solvent. It
must be understood, however, that before or after the differential distribution of binder present in this liquid has been secured, a supplementary binder (e.g. a compounded rubber latex) may be applied if desired, and
3,321,356 Patented May 23, 1967 that surface finishing coating (e.g. of a polyurethane lacquer) may also be applied if desired.
The layer of fibrous material used may take any of a variety of forms. It may for instance be in the nature of a felt, or a fleece. A specific example of the fibrous material layers which may be used is that comprising a web of interpenetrated crimped continuous nylon monofilaments which after needle-punching has been overlaid with a fleece of polypropylene staple fibres, the latter having been needle-punched beforehand and also after being laid on the nylon web. Particularly good results are obtainable if the binder-rich part of the product is derived from fine-denier fibres, egg. by laying one or more fine-denier fleeces on a coarser base web and if desired uniting them by needle-punching. This assists the migration of the binder and promotes continuity and fine poros ity in the binder-rich surface.
By the differential-heating technique of the present invention, it is possible to obtain flexible sheet materials having a smooth, cfinely porous surface of binder on one side and a surface with much less or no binder on the other side. We have found that the present technique has (in the field for which it is intended) substantial advantages over the other techniques for differentially distributing the binder which we have considered; these other techniques were (1) surface application of binder, which was liable to give a rough surface or alternatively a readily detached non-porous stratum, (2) surface accumulation by pressing, which was liable to give undifferentiated ob verse and reverse surfaces, (3) gravitation to a lowermost surface, which was liable to give a non-porous surface layer and which in any case required an open fibrous layer and a high proportion of binder, and (4) capillary migration, which was liable to give a rough and uneven surface.
The invention will now be illustrated by way of example only with reference to the accompanying drawing, in which- FIGURE 1 is a cross-sectional view of a mat of fibres prior to impregnation with a binder;
FIGURE 2 is a cross-sectional view of the' mat subsequent to impregnation with a binder and after differential distribution of the binder;
FIGURE 2A is an enlarged view of the uppermost layer of the mat shown in FIGURE 2; and
FIGURE 3 is a cross-sectional view of the mat subsequent to impregnation with a second binder.
Referring now to the drawing, FIGURE 1 shows a cross-section through a mat 1 formed from a layer of crimped continuous nylon filaments 2 and a layer of polypropylene staple fibres 3. The mat 1 is made by laying a needle-punched mat of the staple fibres 3 on the layer of continuous filaments 2 and needlingthe assembled layers together.
FIGURE 2 shows a cross-section through the mat after the mat has been impregnated with a polyurethane binder composition 5, and after differential distribution of this binder composition. The polypropylene staple fibre layer contains the major proportion of the binder composition and the layer of staple fibres and binder is shown by the reference numeral 4 in FIGURE 2. The polypropylene fibres 3 are embedded in the binder 5 as shown in the enlarged cross-section through the layer 4 in FIGURE 2A. The layer 4 also contains small air-spaces 6.
The mat shown in FIGURE 3 contains a rubber composition (second binder composition) 7 which is applied to the mat shown in FIGURES 2 and 2A and is then cured. As shown in FIGURE 3, the rubber composition 7 penetrates the polyurethane layer 4 and fills the airspaces 6 of this layer.
The following examples illustrate'the invention.
3 Example I A web of crimped continuous 6-denier nylon 66 monofilaments, laid under light tension in the form of parallel continuous yarns and subsequently relaxed, and which weighed approximately 20 grams per sq. ft. in the relaxed condition, was passed once through a needle-punching machine and then covered with a fleece of randomly oriented 3-denier polypropylene fibre of 2 /2" staple length which had previously been needle-punched and weighed approximately 6 grams per sq. ft. The assembly was then needled a further 4 times. A one foot square of the resulting composite felt weighing 24 grams was laid, nylon side downwards, on a steel plate covered With a polyethylene foil. 50 grams of a freshly prepared solution containing 96 parts by weight of the liquid polyurethane rubber Adiprene L-100, 4 parts of trimethylolpropane and 1 part of stannous octoate in 100 parts of dry acetone, were poured centrally on to the top surface of the felt, into which the whole of it soaked and to some extent spread out.
The top surface was immediately covered with a sheet of polyethylene foil and then another steel plate. The assembly was placed in a cold platen press and compressed without spacers under a pressure of 230 lbs.-/ sq. in. for 75 seconds to distribute the solution uniformly. About 10 grams of the solution extruded at the edges and was not recovered. The press was then opened and the felt removed. At this stage it was a completely wetted open structure about 4 mm. thick. It was immediately laid, polypropylene fibre side upwards, between two polypropylene sheets and placed in a mould fitted with spacers to give a depth of 1 /2 mm. between the polypropylene sheets.
This assembly was placed in a press having the bottom platen at room temperature and the top platen at 100 C., and pressed to 230 lbs/sq. in. After ten minutes the temperature of both platens was raised to 110 C. and pressing continued at this temperature for a further ten minutes. The press was then cooled and opened and the product removed. It consisted of a 2 mm. thick sheet having a supple feel and a smooth finely porous top surface consisting of compacted polypropylene fibres embedded in porous elastomeric polyurethane, the reverse (nylon fibre) surface of the sheet being denuded of polyurethane.
This product had a tensile strength of 750 lbs./sq. in. and an elongation at break figure of 85%. After applying a polyurethane lacquer finish to the top surface it had a very leather-like appearance, and after impregnation with 50 grams dry weight of rubber latex and 'bufiing the back surface, a very leather-like product was obtained having a tensile strength of over 2000 lbs./sq. in., an elongation at break figure of over 80%, a flex life greater than 1 million cycles on the standard (SATRA) vamp-flexing machine, and a water-vapour permeability of 0.43 mg./sq. cm./hr. It conformed also with other typical natural leather test specifications.
Example 11 The procedure of Example I was repeated except that the composite web employed consisted of grams per sq. ft. of continuous nylon 66, 5 grams per sq. ft. of 3-denier polypropylene staple and a top layer of 5 grams per sq. ft. of lVz-denier nylon 66 staple.
The product was very similar to that of Example I and after impregnation and coating had a flex life of over 3.8 million cycles.
Example III A felt was prepared, impregnated and pressed exactly as in Example II except that the spacers were adjusted to compress the product to 1.0 mm.
The top surface of the product was of the same character as before, but the back surface, although of an open fibrous texture, retained sufficient polyurethane for the material to serve as an artificial leather without any further impregnation treatment.
Example IV The procedure of Example I was repeated exactly except that the random fleece of polypropylene was replaced by two laps of PAM-denier, high-crimp, 1 /2"-staple nylon 66, each weighing 3.5 grams/sq. ft. The first of these laps was laid with its principal fibre direction crossing the underlying nylon yarns at an angle of 45 and the second was laid at to the first, i.e. also crossing the underlying yarns at 45 but inclined in the opposite direction.
The product obtained after impregnation with rubber latex and bufiing the back surface was similar in appearance to the corresponding product of Example I and gave the following test data:
Direction of measurement Sample 1.4 mm. thick Stitch tear (lb./in.) 710 590 Tongue tear (lb/in.)
Example V A web was prepared as in Example I and laid as before on a steel plate covered with a polyethylene foil. 60 grams of a freshly prepared compounded ammonia-preserved natural rubber latex mix of the following composition was poured centrally on to the top of the felt:
Parts by weight Natural rubber latex (60% dry rubber content) 100.0 Aqueous solution of potassium oleate (15 g./ g.
solution) 6.7 Aqueous dispersion of sulphur (50 g./ 100 g. dispersion) 2.0 Aqueous dispersion of dibetanaphthyl-p-phenylene diamine (40 g./ 100 g. dispersion) 2.5 Aqueous dispersion of zinc diethyldithiocarbamate (5O g./100 g. dispersion) 1.0 Aqueous dispersion of zinc salt of mercaptobenzothiazole (50 g./ 100 g. dispersion) 3.0 Water 54.0 Aqueous dispersion of zinc oxide (50 g./ 100 g.
dispersion) added just before use 6.0
The latex mix soaked into the web and to some extent spread out.
The top surface was immediately covered with a sheet of polyethylene foil and then another steel plate. The assembly was placed in the press and compressed without spacers at 230 lb./sq. in. for 30 seconds. About 15 grams of the latex mix extruded at the edges and was not recovered. The press was opened and the felt removed. At this stage it was a completely wetted, open structure about 4 mm. thick. It was immediately laid, polypropylene fibre side upwards, between two polypropylene sheets and placed in a mould fitted with spacers to give a depth of 1.5 mm.
The assembly was pressed at 230 lb./sq. in. with the bottom platen initially att about 40 C. and the top platen at C. After 20 minutes the temperature of the bottom platen had gradually increased to about 80 C., the top platen temperature remaining at 130 C. The press was then cooled and opened, and the product removed. It consisted of a fully dried and cured 1.5 mm. thick sheet. It had an extremely supple feel and a smooth finely porous top surface consisting of polypropylene fibres embedded in a porous vulcanized latex rubber, the reverse (nylon fibre) surface of the sheet being denuded of rubber and having acquired an attractively smooth surface by heat setting in the presence of the steam from the latex evaporation. dicate sufliciently high-level properties to yield a good leather replacement material after a supplementary and more uniform impregnation with a further quantity of binder applied from the back.
A web of the crimped continuous 6-denier nylon 66 monofil was relaxed as before and then needle-punched 6 times from alternate sides. It then weighed 19 grams per sq. ft.
An emulsion of a liquid polyurethane rubber (Adiprene 11-100) was prepared as follows. 100 parts of Adiprene L-lOO were dissolved in 50 parts of toluene and then 4 parts of the addition product of ethylene oxide and nonylphenol sold under the trade name of Nonidet P-40 were stirred in. Separately, the following ingredients were mixed with 66 parts of water: 30 parts of a solution in 90 parts of water of 10 parts of sodium dodecyl sulphate, 20 parts of a solution in 95 parts of water of 5 parts of dioctyl sodium sulphosuccinate sold under the trade name Manoxol N, and 30 parts of an aqueous solution of ammonium caseinate made by dissolving in 990 parts of water 100 parts of lactic casein, 1 part of sodium pentachlorophenate and 9 parts of aqueous ammonia solution of specific gravity 0.880. The above Adiprene solution was slowly poured with high-speed stirring into the aqueous liquid, yielding an oil-in-water-type emulsion which remained colloidally stable for many weeks. The fieshly prepared emulsion was matured at room temperature for 24 hours by which time test films dried at room temperature on a glass plate consisted of coherent, substantially tack-free elastomer.
The nylon web (1 sq. ft.) was treated with 50 grams of this matured emulsion and then given the same subsequent treatment as the web in Example V. (The extrusion loss in the first pressing was 14 grams of emulsion.)
The product after the second pressing was a fully dried and cured 1.5 mm.-thick strong flexible sheet having a smooth finely porous top surface and a smooth open back surface devoid of Adiprene.
Example VII A 1 ft. square nylon web similar to that in Example VI but weighing 23 grams was first impregnated substantially uniformly throughout its thickness with Adiprene binder by the following technique. 50 grams of a freshly prepared solution of 96 parts of Adiprene, 4 parts of trimethylolpropane and 1 part of stannous octoate, all dissolved in 400 parts of dry acetone, were poured on centrally, and the cold pressing applied as before. This caused the extrusion of 20 grams of the solution. On release, the remaining 30 grams of solution were found to be almost evenly distributed throughout the web. The web was immediately transferred to a well-ventilated hotair oven at 80 C. for 5 minutes, by the end of which time the acetone had substantially all evaporated before any appreciable drainage of solution had had time to occur. At this stage the Adiprene was weak and tacky. The web was then pressed to 1.5 mm. for 15 minutes in a press having both its platens at 100 C., yielding a fully cured 1.5 mm. thick sheet.
It gave the following test data which inp solution and technique described in Example I. No excess solution exuded in the cold pressing and the web, already 1.5 mm. thick in the wet state, was held at 1.5 mm. during the hot pressing.
The final product was a leather-like sheet having a strongly increasing graduation of Adiprene binder content from the bottom to the top surface, and this top surface had the smooth and finely porous quality characteristic of the invention.
Having now described our invention, what we claim is:
1. A method of producing flexible sheet material which comprises distributing throughout a layer of fibrous material, a liquid comprising a binder for the fibres of said fibrous material and a vaporisable vehicle for said binder and applying heat to one surface of said layer to raise its temperature adjacent this surface above the tempera ture adjacent to the other surface to secure a differential distribution and a concentration of said binder adjacent said heated surface to remove the vehicle by vaporization and to heat-cure said binder.
2. A method according to claim 1, in which the layer of fibrous material incorporating the liquid comprising the binder and vaporisable vehicle, is confined and compressed between plates while the differential heating is performed.
3. A method according to claim 2, in which one of the plates is heated positively and the other is left unheated.
4. A method according to claim 2 in which one of the plates is heated positively and the other is cooled positively.
5. A method according to claim 4 using a solution of an intermediate chemical system reacting to form a polyurethane rubber in an organic solvent.
6. A method according to claim 1, in which the liquid comprising a binder and a vaporisable vehicle is a solution.
7. A method according to claim 5, using a solution of a polyurethane rubber in an organic solvent.
8. A method according to claim 1, in which the liquid comprising a binder and a vaporisable vehicle is a rubber latex.
9. A method according to claim 1 in which a supplementary binder is applied after applying said liquid.
10. A method according to claim 9 in which the supplementary binder is a compounded rubber latex.
11. A method according to claim 1 in which the layer of fibrous material incorporating the liquid comprising the binder and vaporisable vehicle, is confined and compressed between belts while the differential heating is performed in a continuous process.
12. A method according to claim 11 in which one of the belts is heated positively and the other is left unheated.
13. A method according to claim 11 in which one of the belts is heated positively and the other is cooled positively.
14. A method according to claim 1 in which the layer of fibrous material comprises a web of needle-punched interpenetrated crimp continuous nylon monofilaments overlaid with a fleece of needle-punched polypropylene staple fibres and needle-punched on the nylon web.
15. A method according to claim 1 in which the liquid comprises a binder and a vaporisable vehicle is an aqueous emulsion of a solution of an elastomer in an organic solvent.
16. Flexible sheet material which comprises a layer of matted fibrous material and a flexible binder for said fibres differentially distributed throughout said layer, the concentration of said binder being greater adjacent to one surface of said layer than adjacent the other surface of said layer.
17. The flexible sheet material of claim 16 in which said material'has a smooth, finely porous surface of compacted fibres and binder.
18. The flexible sheet material of claim 16 in which said layer of matted fibrous material comprises a layer of interpenetrated continuous monofilaments and a layer superposed on the above layer of randomly oriented fibres, and in which said concentration of binder is greatest in said superposed layer.
19. The flexible sheet material of claim 18 in which said continuous monofilaments are nylon and said 10 randomly oriented fibres are polyethylene.
20. The flexible material of claim 18 in which said layers of continuous interpenetrated continuous monofilaments and randomly oriented fibres have been united by needle-punching.
References Cited by the Examiner UNITED STATES PATENTS 2,970,365 2/ 1961 Morgenstern 28--72.2 X 2,994,940 8/1961 Ferrell et a1 38-74 X 3,141,809 7/1964 Maio et a1. 161-155 X MERVIN STEIN, Primary Examiner.
L. K. RIMRODT, Assistant Examiner.
Claims (1)
16. FLEXIBLE SHEET MATERIAL WHICH COMPRISES A LAYER OF MATTED FIBROUS MATERIAL AND A FLEXIBLE BINDER FOR SAID FIBRES DIFFERENTIALLY DISTRIBUTED THROUGHOUT SAID LAYER, THE CONCENTRATION OF SAID BINDER BEING GREATER ADJACENT TO ONE SURFACE OF SAID LAYER THEN ADJACENT THE OTHER SURFACE OF SAID LAYER.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB30289/63A GB1083037A (en) | 1963-07-31 | 1963-07-31 | Improvements relating to the production of flexible sheet materials |
Publications (1)
Publication Number | Publication Date |
---|---|
US3321356A true US3321356A (en) | 1967-05-23 |
Family
ID=10305282
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US381876A Expired - Lifetime US3321356A (en) | 1963-07-31 | 1964-07-10 | Production of flexible sheet materials |
Country Status (4)
Country | Link |
---|---|
US (1) | US3321356A (en) |
DE (1) | DE1469320A1 (en) |
FR (1) | FR1403417A (en) |
GB (1) | GB1083037A (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3458387A (en) * | 1966-06-14 | 1969-07-29 | Monsanto Co | Flexible non-woven sheet material and method of making the same |
FR2053364A1 (en) * | 1969-07-31 | 1971-04-16 | Kalle Ag | |
US3956783A (en) * | 1974-10-21 | 1976-05-18 | Phillips Petroleum Company | Mattress |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2970365A (en) * | 1958-08-04 | 1961-02-07 | Morgenstern David | Needled fabric and method |
US2994940A (en) * | 1958-04-15 | 1961-08-08 | Us Rubber Co | Plastic coated fabric and method of making same |
US3141809A (en) * | 1957-06-26 | 1964-07-21 | Johns Manville Fiber Glass Inc | Mineral fiber laminate and method of making same |
-
1963
- 1963-07-31 GB GB30289/63A patent/GB1083037A/en not_active Expired
-
1964
- 1964-07-10 US US381876A patent/US3321356A/en not_active Expired - Lifetime
- 1964-07-27 DE DE19641469320 patent/DE1469320A1/en active Pending
- 1964-07-30 FR FR983580A patent/FR1403417A/en not_active Expired
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3141809A (en) * | 1957-06-26 | 1964-07-21 | Johns Manville Fiber Glass Inc | Mineral fiber laminate and method of making same |
US2994940A (en) * | 1958-04-15 | 1961-08-08 | Us Rubber Co | Plastic coated fabric and method of making same |
US2970365A (en) * | 1958-08-04 | 1961-02-07 | Morgenstern David | Needled fabric and method |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3458387A (en) * | 1966-06-14 | 1969-07-29 | Monsanto Co | Flexible non-woven sheet material and method of making the same |
FR2053364A1 (en) * | 1969-07-31 | 1971-04-16 | Kalle Ag | |
US3956783A (en) * | 1974-10-21 | 1976-05-18 | Phillips Petroleum Company | Mattress |
Also Published As
Publication number | Publication date |
---|---|
GB1083037A (en) | 1967-09-13 |
DE1469320A1 (en) | 1969-01-30 |
FR1403417A (en) | 1965-06-18 |
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