US3400004A - Novel coated and molded woven fabrics and method of making the same - Google Patents

Novel coated and molded woven fabrics and method of making the same Download PDF

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Publication number
US3400004A
US3400004A US260058A US26005863A US3400004A US 3400004 A US3400004 A US 3400004A US 260058 A US260058 A US 260058A US 26005863 A US26005863 A US 26005863A US 3400004 A US3400004 A US 3400004A
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Prior art keywords
yarns
coated
warp
weft
fabric
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US260058A
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William A Corry
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Interchemical Corp
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Interchemical Corp
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Priority to NL302327D priority Critical patent/NL302327A/xx
Application filed by Interchemical Corp filed Critical Interchemical Corp
Priority to US260058A priority patent/US3400004A/en
Priority to GB43897/63A priority patent/GB1046500A/en
Priority to ES293827A priority patent/ES293827A1/en
Priority to CH1545863A priority patent/CH494854A/en
Priority to CH1545863D priority patent/CH1545863A4/xx
Priority to DE19631560843 priority patent/DE1560843A1/en
Priority to FR959409A priority patent/FR1378725A/en
Priority to SE2053/64A priority patent/SE317945B/xx
Application granted granted Critical
Publication of US3400004A publication Critical patent/US3400004A/en
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Classifications

    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
    • D03D15/217—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based natural from plants, e.g. cotton
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
    • D03D15/225—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based artificial, e.g. viscose
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/49—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads textured; curled; crimped
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/14—Processes for the fixation or treatment of textile materials in three-dimensional forms
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
    • D06M23/18—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment for the chemical treatment of borders of fabrics or knittings; for the thermal or chemical fixation of cuttings, seams or fibre ends
    • 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
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • 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
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0025—Rubber threads; Elastomeric fibres; Stretchable, bulked or crimped fibres; Retractable, crimpable fibres; Shrinking or stretching of fibres during manufacture; Obliquely threaded fabrics
    • D06N3/0029—Stretchable fibres; Stretching of fibres during manufacture
    • 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
    • D06N3/06—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 polyvinylchloride or its copolymerisation products
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D10B2201/02—Cotton
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/20—Cellulose-derived artificial fibres
    • D10B2201/22—Cellulose-derived artificial fibres made from cellulose solutions
    • D10B2201/24—Viscose
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/061—Load-responsive characteristics elastic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses
    • 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
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31935—Ester, halide or nitrile of addition polymer
    • 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
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31938—Polymer of monoethylenically unsaturated hydrocarbon
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y10T442/3228—Materials differ
    • Y10T442/326—Including synthetic polymeric strand material
    • Y10T442/3268—Including natural strand material
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/322—Warp differs from weft
    • Y10T442/3228—Materials differ
    • Y10T442/326—Including synthetic polymeric strand material
    • Y10T442/3276—Including polyamide strand material
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/3301—Coated, impregnated, or autogenous bonded
    • Y10T442/3317—Woven fabric contains synthetic polymeric strand material

Definitions

  • Coated fabrics conventionally comprise a textile substrate coated with a predominantly thermoplastic resin coating.
  • Thermoplastic resins conventionally used in coated fabrics include vinyl chloride resins, polystrenes and acrylic resins.
  • the coated fabric In preparing coated fabric articles to be used in up holstery, the coated fabric is conventionally patterned, cut and sewed or seamed together to form the selected shape in a manner much the same as that applied to noncoated fabrics.
  • novel woven textile fabric which when coated with a conventional thermoplastic coating provides a novel coated fabric which may be heat shaped or molded into an article of selected shape thus eliminating the costly and time consuming patterning, cutting and seaming operations of conventional practices.
  • the novel woven textile of my invention comprises a warp of polypropylene yarns and weft of yarns selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns such as cotton and slack mercerized regenerated cellulose yarns.
  • a warp consisting essentially of polypropylene yarns and a weft consisting essentially of either natural or regenerated cellulose yarns has been found very important in the coating and the heat shaping of the coated fabric. It is essential that the yarns in the warp do not distort at the temperatures (225 to 290 F.) of the conventional calendering operation which is the most efficient and effective means for preparing the coated fabrics of this invention. Further, the yarns of the warp must be thermoplastic to the extent that they readily flow at the temperatures and pressures of conventional heat shaping.
  • weft yarns must not be affected by the temperatures of the coating operation and must primarily provide the adhesion between the textile substrate and the coating composition since virtually any thermoplastic yarn which could be used in the warp would not display the adhesion required of coated fabrics.
  • the Weft yarns must be readily mechanically extendable by the pressures of the heat shaping or molding operations.
  • the coating composition may suitably be selected from any of the conventional thermoplastic coating compositions for coated fabrics such as polystyrenes and acrylic resins, best results are obtained using a conventional vinyl chloride resin coating composition.
  • vinyl chloride resin is meant to include both vinyl chloride homopolymers and copolymers of predominantly vinyl chloride with other monomers such as vinyl acetate.
  • the coating composition may of course contain suitable plasticizers, pigments and stabilizers.
  • the thermoplastic coating is preferably applied to the substrateby calendering.
  • the temperatures of the rollers and the coating composition during calendering may be as high as 330 F.
  • the temperatures of the fabric itself will of course be considerably lower because of short contact times and resulting temperatures after heat exchange.
  • the temperatures are some times high enough to produce the tendency of shrinkage in the polypropylene yarn of the warp. This tendency is readily compensated for by keeping the warp under tension during coating.
  • the customary slight tension exerted on the warp in drawing the fabric as a web through the calendering rollers has been found to be more than sufiicient to compensate for the tendecy of the web to shrink.
  • the coated fabrics of this invention may be heat shaped or molded.
  • the fabrics by means of the polypropylene warp which flows, retain their shape after being molded.
  • the shaping or molding is carried out over a temperature range preferably from 280 to 320 F.
  • the molding techniques which may be used include plug molding which employs a male die, compression forming which uses both male and female dies and vacuum forming.
  • Example 1 A woven fabric constructed of a warp consisting wholly of polypropylene yarn of about 223 denier and 1 ply, 52 warp ends per inch and a weft consisting wholly of textured nylon yarn of about 166 denier and 2 ply, 48 weft ends per inch (weft contraction 23.2%), said fabric having a weight of 2.84 oz. per square yard is coated by calendering at a roller temperature of about 310 to 320 F., the warp being under tension to prevent any shrinkage of the polypropylene, 'with a conventional vinyl chloride resin coating composition comprising:
  • a resin containinig vinyl chloride and 5% vinyl acetate Dioctyl phthalate plasticizer 70 TiO pigment 10 Calcium carbonate 20 Calcium stearate 1 Barium-cadmium laurate stabilizer 2 The coating thickness is about 15 mils.
  • the coated fabric is then cooled, after which the coated fabric is molded by vacuum molding.
  • the coated fabric a is clamped into a conventional vacuum molding apparatus and heated by infrared means to about 300 F.
  • the clamp is then dropped and a vacuum pulled which draws the coated fabric against the contours of the selected mold.
  • the contoured coated fabric is permitted to cool.
  • the product is a contoured coated fabric article of a selected shape.
  • Example 2 A woven fabric constructed of a warp consisting wholly of polypropylene yarn of about 218 denier and 1 ply, 46 warp ends per inch and a weft consisting wholly of cotton yarn of 7.85 s yarn number, 1 ply 51.3 weft ends per inch, said fabric having a weight of 3.88 oz. per square yard is mercerized by immersion without tension in a 25% solution of NaOH in water at about 68 F. for 30 minutes. The fabric is then rinsed in water, soured in a 5% acetic acid solution and rinsed again with water.
  • the fabric is then coated in accordance with the procedure of Example 1 with the coating composition of Example 1. Then following the procedure of Example 1, the resulting coated fabric is vacuum molded into a selected shape.
  • Example 3 A woven fabric constructed of a warp consisting wholly of polypropylene yarns and a weft consisting wholly of viscose rayon yarns is first slack mercerized in accordance with the procedure of Example 2. The fabric is then coated in accordance with the procedure of Example 1 with the coating composition of Example 1. Then following the procedure of Example 1, the resulting coated fabric is vacuum molded into a selected shape.
  • a coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of stetchable textured nylon yarns and a thermoplastic resin coating on said substrate.
  • a coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of slack mercerized cotton yarns and a thermoplastic resin coating on said substrate.
  • a coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of slack mercerized rayon yarns and a thermoplastic resin coating on said substrate.
  • thermoplastic resin is a vinyl chloride resin.
  • thermoplastic resin is a vinyl chloride resin.
  • thermoplastic resin is a vinyl chloride resin.
  • a heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of a yarn selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns and slack mercerized regenerated cellulose yarns, said substrate carrying a coating of a thermoplastic resin.
  • a heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of stretchable textured nylon yarns, said substrate carrying a coating of a vinyl chloride resin.
  • a heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of slack mercerized cotton yarns, said substrate carrying a coating of a thermoplastic resin.
  • a method of making a coated fabric article comprising (1) applying with a heat thermoplastic coating composition to a textile substrate comprising a warp of polypropylene yarns and a weft of a yarn selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns and slack mercerized regenerated cellulose yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.
  • a method of making a coated fabric article comprising (1) applying with heat a coating composition of a vinyl chloride resin to a textile substrate comprising a warp of polypropylene yarns and a weft of stretchable textured nylon yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.
  • a method of making a coated fabric article comprising (1) applying with heat a coating composition of a vinyl chloride resin to a textile substrate comprising a warp of polypropylene yarns and a weft of slack mercerized cotton yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.

Description

United States Patent "ice 3,400,004 NOVEL COATED AND MOLDED WOVEN FABRICS AND METHOD OF MAKING THE SAME William A. Corry, Toledo, Ohio, assignor to Interchemical Corporation, New York, N.Y., a corporation of Ohio No Drawing. Filed Feb. 20, 1963, Ser. No. 260,058 12 Claims. (Cl. 117-7) This invention relates to novel woven textile fabrics and particularly to novel coated fabrics made from said woven fabrics. This invention further relates to heat shaped articles formed from said coated fabrics.
There is at present a wide demand for articles made of coated fabrics, particularly in the upholstery field. Coated fabrics conventionally comprise a textile substrate coated with a predominantly thermoplastic resin coating. Thermoplastic resins conventionally used in coated fabrics include vinyl chloride resins, polystrenes and acrylic resins.
In preparing coated fabric articles to be used in up holstery, the coated fabric is conventionally patterned, cut and sewed or seamed together to form the selected shape in a manner much the same as that applied to noncoated fabrics.
I have now discovered a novel woven textile fabric which when coated with a conventional thermoplastic coating provides a novel coated fabric which may be heat shaped or molded into an article of selected shape thus eliminating the costly and time consuming patterning, cutting and seaming operations of conventional practices. The novel woven textile of my invention comprises a warp of polypropylene yarns and weft of yarns selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns such as cotton and slack mercerized regenerated cellulose yarns.
The combination of a warp consisting essentially of polypropylene yarns and a weft consisting essentially of either natural or regenerated cellulose yarns has been found very important in the coating and the heat shaping of the coated fabric. It is essential that the yarns in the warp do not distort at the temperatures (225 to 290 F.) of the conventional calendering operation which is the most efficient and effective means for preparing the coated fabrics of this invention. Further, the yarns of the warp must be thermoplastic to the extent that they readily flow at the temperatures and pressures of conventional heat shaping. Concurrently, the weft yarns must not be affected by the temperatures of the coating operation and must primarily provide the adhesion between the textile substrate and the coating composition since virtually any thermoplastic yarn which could be used in the warp would not display the adhesion required of coated fabrics. In addition, the Weft yarns must be readily mechanically extendable by the pressures of the heat shaping or molding operations.
So far as is know, with the exception of my novel fabrics, there are no existing coated fabrics which can be heat shaped into articles. Uncoated woven fabrics of Dynel (copolymer of acrylonitrile and vinyl chloride) yarn are being heat shaped to form articles such as hat-s, stiffened linings for clothing and packaging for delicate instruments. However, coated fabrics of Dynel yarns have not been produced primarily because such yarns display very poor adhesion to the thermoplastic coatings used for coated fabrics. In addition, Dynel fabrics are too heat sensitive to be coated by the conventional calendering methods. Available polyethylene yarns have been found not to provide a suitable substitute for the polypropylene fibers of the warp. Both low and high density polyethylene become distorted at the temperatures of the conventional calendering operations.
3,400,004 Patented Sept. 3, 1968 As has been previously mentioned the yarns of the weft must be in a stretchable condition. Textured nylon provides a very suitable yarn. Textured or bulked yarns are those which have been treated to have a relatively high potential stretch. The term textured is meant to in clude crimped, curled, looped and heat set yarns. When the weft comprises cellulose yarns such as cotton or rayon, these yarns are preferably mercerized to their stretchable condition. This is preferably accomplished by slack mercerizing (without tension) the fabric containing the cotton or rayon weft prior to coating the fabric.
While the coating composition may suitably be selected from any of the conventional thermoplastic coating compositions for coated fabrics such as polystyrenes and acrylic resins, best results are obtained using a conventional vinyl chloride resin coating composition. The term vinyl chloride resin is meant to include both vinyl chloride homopolymers and copolymers of predominantly vinyl chloride with other monomers such as vinyl acetate. The coating composition may of course contain suitable plasticizers, pigments and stabilizers.
The thermoplastic coating is preferably applied to the substrateby calendering. The temperatures of the rollers and the coating composition during calendering may be as high as 330 F. However, the temperatures of the fabric itself will of course be considerably lower because of short contact times and resulting temperatures after heat exchange. However, it has been noticed that the temperatures are some times high enough to produce the tendency of shrinkage in the polypropylene yarn of the warp. This tendency is readily compensated for by keeping the warp under tension during coating. The customary slight tension exerted on the warp in drawing the fabric as a web through the calendering rollers has been found to be more than sufiicient to compensate for the tendecy of the web to shrink.
The coated fabrics of this invention may be heat shaped or molded. The fabrics, by means of the polypropylene warp which flows, retain their shape after being molded. The shaping or molding is carried out over a temperature range preferably from 280 to 320 F. The molding techniques which may be used include plug molding which employs a male die, compression forming which uses both male and female dies and vacuum forming.
It should be noted that in the present specification and claims, all proportions are by weight unless otherwise stated.
The following examples will illustrate the practice of this invention:
Example 1 A woven fabric constructed of a warp consisting wholly of polypropylene yarn of about 223 denier and 1 ply, 52 warp ends per inch and a weft consisting wholly of textured nylon yarn of about 166 denier and 2 ply, 48 weft ends per inch (weft contraction 23.2%), said fabric having a weight of 2.84 oz. per square yard is coated by calendering at a roller temperature of about 310 to 320 F., the warp being under tension to prevent any shrinkage of the polypropylene, 'with a conventional vinyl chloride resin coating composition comprising:
Parts by weight A resin containinig vinyl chloride and 5% vinyl acetate Dioctyl phthalate plasticizer 70 TiO pigment 10 Calcium carbonate 20 Calcium stearate 1 Barium-cadmium laurate stabilizer 2 The coating thickness is about 15 mils.
The coated fabric is then cooled, after which the coated fabric is molded by vacuum molding. The coated fabric a is clamped into a conventional vacuum molding apparatus and heated by infrared means to about 300 F. The clamp is then dropped and a vacuum pulled which draws the coated fabric against the contours of the selected mold. The contoured coated fabric is permitted to cool. The product is a contoured coated fabric article of a selected shape.
Example 2 A woven fabric constructed of a warp consisting wholly of polypropylene yarn of about 218 denier and 1 ply, 46 warp ends per inch and a weft consisting wholly of cotton yarn of 7.85 s yarn number, 1 ply 51.3 weft ends per inch, said fabric having a weight of 3.88 oz. per square yard is mercerized by immersion without tension in a 25% solution of NaOH in water at about 68 F. for 30 minutes. The fabric is then rinsed in water, soured in a 5% acetic acid solution and rinsed again with water.
The fabric is then coated in accordance with the procedure of Example 1 with the coating composition of Example 1. Then following the procedure of Example 1, the resulting coated fabric is vacuum molded into a selected shape.
Example 3 A woven fabric constructed of a warp consisting wholly of polypropylene yarns and a weft consisting wholly of viscose rayon yarns is first slack mercerized in accordance with the procedure of Example 2. The fabric is then coated in accordance with the procedure of Example 1 with the coating composition of Example 1. Then following the procedure of Example 1, the resulting coated fabric is vacuum molded into a selected shape.
What is claimed is:
1. A coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of stetchable textured nylon yarns and a thermoplastic resin coating on said substrate.
2. A coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of slack mercerized cotton yarns and a thermoplastic resin coating on said substrate.
3. A coated fabric comprising a textile substrate having a warp of polypropylene yarns and a weft of slack mercerized rayon yarns and a thermoplastic resin coating on said substrate.
4. The coated fabric of claim 1 wherein said thermoplastic resin is a vinyl chloride resin.
5. The coated fabric of claim 2 wherein said thermoplastic resin is a vinyl chloride resin.
6. The coated fabric of claim 3 wherein said thermoplastic resin is a vinyl chloride resin.
7. A heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of a yarn selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns and slack mercerized regenerated cellulose yarns, said substrate carrying a coating of a thermoplastic resin.
8. A heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of stretchable textured nylon yarns, said substrate carrying a coating of a vinyl chloride resin.
9. A heat shaped coated fabric comprising a contoured substrate having a warp of polypropylene yarns and a weft of slack mercerized cotton yarns, said substrate carrying a coating of a thermoplastic resin.
10. A method of making a coated fabric article comprising (1) applying with a heat thermoplastic coating composition to a textile substrate comprising a warp of polypropylene yarns and a weft of a yarn selected from the group consisting of stretchable textured nylon yarns, slack mercerized natural cellulose yarns and slack mercerized regenerated cellulose yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.
11. A method of making a coated fabric article comprising (1) applying with heat a coating composition of a vinyl chloride resin to a textile substrate comprising a warp of polypropylene yarns and a weft of stretchable textured nylon yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.
12. A method of making a coated fabric article comprising (1) applying with heat a coating composition of a vinyl chloride resin to a textile substrate comprising a warp of polypropylene yarns and a weft of slack mercerized cotton yarns, said warp being maintained under tension during the application of the coating and (2) heat molding said coated substrate to a selected shape.
References Cited UNITED STATES PATENTS 1,370,597 3/1921 Lambert 156-161 2,827,414 3/1958 Bussard et al 16178 X 2,942,327 6/1960 Corry 161-91 2,810,184 10/1957 Sherman 139-421 X 3,142,109 7/1964

Claims (1)

10. A METHOD OF MAKING A COATED FABRIC ARTICLE COMPRISING (1) APPLYING WITH A HEAT THERMOPLASTIC COATING COMPOSITIONS TO A TEXTILE SUBSTRATE COMPRISING A WARP OF POLYPROPYLENE YARNS AND A WEFT OF A YARN SELECTED FROM THE GROUP CONSISTING OF STRETCHABLE TEXTURED NYLN YARNS, SLACK MERCERIZED NATURAL CELLULOSE YARNS AND SLACK MERCERIZED REGENERATED CELLULOSE YARNS, SAID WARP BEING MAINTAINED UNDER TENSION DURING THE APPLICATION OF THE COATING AND (2) HEAT MOLDING SAID COATED SUBSTRATE TO A SELECTED SHAPE.
US260058A 1963-02-20 1963-02-20 Novel coated and molded woven fabrics and method of making the same Expired - Lifetime US3400004A (en)

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NL302327D NL302327A (en) 1963-02-20
US260058A US3400004A (en) 1963-02-20 1963-02-20 Novel coated and molded woven fabrics and method of making the same
GB43897/63A GB1046500A (en) 1963-02-20 1963-11-06 Improvements in woven fabrics, coated fabrics, and moulded articles
ES293827A ES293827A1 (en) 1963-02-20 1963-11-25 Improvements introduced in the manufacture of textile fabrics (Machine-translation by Google Translate, not legally binding)
CH1545863A CH494854A (en) 1963-02-20 1963-12-16 Mouldable upholstery etc fabric which can be coated
CH1545863D CH1545863A4 (en) 1963-02-20 1963-12-16
DE19631560843 DE1560843A1 (en) 1963-02-20 1963-12-21 Process for making an article from coated fabric
FR959409A FR1378725A (en) 1963-02-20 1964-01-06 New coated textile fabrics
SE2053/64A SE317945B (en) 1963-02-20 1964-02-20

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3470928A (en) * 1967-10-26 1969-10-07 Avisun Corp Polypropylene fabric with modified selvage
US4298648A (en) * 1979-02-28 1981-11-03 Celanese Corporation Belting fabric
US4654254A (en) * 1984-10-11 1987-03-31 The Kendall Company Adhesive tape
US5487936A (en) * 1994-03-21 1996-01-30 Collier Campbell Ltd. Textile fabrics of differential weave comprising multifilament threads wherein individual filaments have a linear density of one decitex or less
US6211099B1 (en) * 1998-07-21 2001-04-03 American Fiber & Finishing Sc, Inc. Substrate fabric
US20070161311A1 (en) * 2000-02-21 2007-07-12 Zimmer Ag Polymer Composition and Molded Articles Produced Therefrom
EP2050802A1 (en) * 2007-10-15 2009-04-22 certoplast Vorwerk & Sohn GmbH Adhesive tape
US20130150764A1 (en) * 2011-12-09 2013-06-13 Tyco Healthcare Group Lp Non-Adherent Wound Dressings and Related Methods Therefor
US9402770B2 (en) 2011-12-09 2016-08-02 Covidien Antimicrobial non-adherent dressings and related methods therefor

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GB2022156B (en) * 1978-04-14 1982-09-22 Toyo Boseki Warp knitted fabric woven or unwoven fabric used in making a liminate
GB2183543A (en) * 1985-11-17 1987-06-10 Murray James Mcleod Laminated fabric
DE3924150A1 (en) * 1989-07-21 1991-01-31 Hoechst Ag DEVELOPABLE TEXTILE FLACES AND NETWORKS MANUFACTURED THEREFROM

Citations (5)

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Publication number Priority date Publication date Assignee Title
US1370597A (en) * 1921-03-08 Method and apparatus for making belts
US2810184A (en) * 1953-06-17 1957-10-22 Harold F Sherman Method for producing a woven elastic bandage or like fabric
US2827414A (en) * 1953-08-11 1958-03-18 Tropi Sales Plastic material and method of preparing same
US2942327A (en) * 1957-08-15 1960-06-28 Landers Corp Coated fabric
US3142109A (en) * 1959-11-27 1964-07-28 Celanese Corp Fabrics

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1370597A (en) * 1921-03-08 Method and apparatus for making belts
US2810184A (en) * 1953-06-17 1957-10-22 Harold F Sherman Method for producing a woven elastic bandage or like fabric
US2827414A (en) * 1953-08-11 1958-03-18 Tropi Sales Plastic material and method of preparing same
US2942327A (en) * 1957-08-15 1960-06-28 Landers Corp Coated fabric
US3142109A (en) * 1959-11-27 1964-07-28 Celanese Corp Fabrics

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3470928A (en) * 1967-10-26 1969-10-07 Avisun Corp Polypropylene fabric with modified selvage
US4298648A (en) * 1979-02-28 1981-11-03 Celanese Corporation Belting fabric
US4654254A (en) * 1984-10-11 1987-03-31 The Kendall Company Adhesive tape
US5487936A (en) * 1994-03-21 1996-01-30 Collier Campbell Ltd. Textile fabrics of differential weave comprising multifilament threads wherein individual filaments have a linear density of one decitex or less
US6211099B1 (en) * 1998-07-21 2001-04-03 American Fiber & Finishing Sc, Inc. Substrate fabric
US20070161311A1 (en) * 2000-02-21 2007-07-12 Zimmer Ag Polymer Composition and Molded Articles Produced Therefrom
US7951237B2 (en) * 2000-02-21 2011-05-31 Smartfiber Ag Polymer composition and molded articles produced therefrom
US20110200776A1 (en) * 2000-02-21 2011-08-18 Smartfiber Ag Polymer Composition and Molded Articles Produced Therefrom
US8496748B2 (en) 2000-02-21 2013-07-30 Smartfiber Ag Polymer composition and molded articles produced therefrom
EP2050802A1 (en) * 2007-10-15 2009-04-22 certoplast Vorwerk & Sohn GmbH Adhesive tape
US20130150764A1 (en) * 2011-12-09 2013-06-13 Tyco Healthcare Group Lp Non-Adherent Wound Dressings and Related Methods Therefor
US9402770B2 (en) 2011-12-09 2016-08-02 Covidien Antimicrobial non-adherent dressings and related methods therefor

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DE1560843A1 (en) 1969-10-09
GB1046500A (en) 1966-10-26
CH1545863A4 (en) 1970-04-30
FR1378725A (en) 1964-11-13
CH494854A (en) 1970-04-30
SE317945B (en) 1969-12-01
ES293827A1 (en) 1964-06-01
NL302327A (en) 1900-01-01

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