US3528147A - Process for preparing non-woven fabrics - Google Patents

Process for preparing non-woven fabrics Download PDF

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Publication number
US3528147A
US3528147A US719310A US3528147DA US3528147A US 3528147 A US3528147 A US 3528147A US 719310 A US719310 A US 719310A US 3528147D A US3528147D A US 3528147DA US 3528147 A US3528147 A US 3528147A
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Prior art keywords
lap
fibers
backing
fabric
support
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US719310A
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English (en)
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Aldo Fior Goteborg
Mauro Navone
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Montedison SpA
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Montedison SpA
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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
    • D04H13/00—Other non-woven fabrics
    • 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
    • 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
    • D04H1/50—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 treatment to produce shrinking, swelling, crimping or curling of fibres

Definitions

  • Non-woven fabrics made up of non-woven lap and backing prepared by making up a non-woven lap comprising a blend of fibers containing from to 50% of heat-shrinkable fibrous component, laying such lap upon a backing, mechanically interlocking portions of the lap with the backing, as by passage of the lap-backing through a needle-punching machine, and heating so as to shrink the fibrous component.
  • the present invention concerns fabrics of the nonwoven type made of synthetic fibers, and further relates to a process for preparing such fabrics.
  • binders in particular, elastomers, acrylic resins, rubber or the like, which serve to bind the lap to the support;
  • binders e.g., acrylic resins and/ or other glue materials frequently results in a number of disadvantages. Thus, often merely a slight rubbing on the fabric surface will result in streakings thereon, by virtue of the resin being exuded from the bottom of the fabric.
  • the fabric exuding the binders will become gummy, tacky or sticky so that it soils easily.
  • the binders in particular on fabrics made up of polyamide and/ or polypropylene fibers, often reduce the light fastness of dyes.
  • the present invention provides a process whereby the above mentioned drawbacks are virtually eliminated.
  • This invention provides fabrics wherein at least one lap comprises a fiber blend containing from 5% to 50% by Weight of a thermo-shrinkable fibrous component, desirably of chlorovinyl material.
  • non-streaking fabrics that are neither gummy nor tacky, and which have a good light fastness for dyes, and show, above all, better wear characteristics such as a minor dirt receptivity and a good abrasion resistance, may be obtained by preparing a fiber blend containing from 5 to 50% of thermo-shrinkable fibrous component, forming a lap from such blend, laying such lap over a support (or forming a sandwich with such support disposed between two such laps), mechanically interlocking the lap with the support, e.g., in conventional manner, as by passing the lap/support through a pinning (needle-punching) machine, optionally applying to the support, as by coating, spraying or dipping, a conventional binder such as a polyvinyl chloride plastisol, and heating the lap/support composite, as by passage through an oven chamber.
  • a conventional binder such as a polyvinyl chloride plastisol
  • thermo-shrinkable chlorovinyl fiber permits one to avoid altogether the use of binders, or alternatively to reduce the amount of binder employed as compared to that amount required by the prior art.
  • binders or alternatively to reduce the amount of binder employed as compared to that amount required by the prior art.
  • acrylic resins or other binders that tend to promote soilability, reduction of light fastness, or the like may be avoided altogether.
  • thermo-shrinkable chlorovinyl fibers reduces or altogether avoids the need of binders inasmuch as during heat treatment, as by passage through an oven or drying chamber, the thermo-shrinkable chlorovinyl fibers shrink, thereby pulling with them the other fibrous component of the blend and hence fixing the lap to the support.
  • the laps to be used in accordance with this invention comprise fiber blends containing from 5 to 50% of thermo-shrinkable fibers, desirably polychlorovinyl fibers, together with one or more other fibrous materials that either are not heat shrinkable or are not so heat shrinkable as the foregoing thermo-shrinkable fibrous material.
  • thermo-shrinkable fibers desirably polychlorovinyl fibers
  • other fibrous materials that either are not heat shrinkable or are not so heat shrinkable as the foregoing thermo-shrinkable fibrous material.
  • Particularly suitable for use as such other fibrous material are polyamide, polyester, polypropylene or acrylic fibers, optionally modified by the addition of modifying agents so as to increase the dyability.
  • thermo-shrinkable polychlorovinyl fibers are commonly known fibers consisting substantially of polymers of vinylchloride, i.e., polyvinyl chloride or copolymers of vinyl chloride with another ethylenically unsaturated monomer copolymerizable therewith, such polymers or copolymers being used either alone or in admixture with another polymeric material such as highly chlorinated polyvinyl chloride, nitrocellulose, or the like.
  • Such chlorovinyl fibers are prepared by conventional wet or dry spining of, e.g., polymers or copolymers of vinyl chloride, such polymeric materials being obtained by known emulsion, suspension or bulk polymerization processes.
  • the support is generally in the form of a fabric backing made up of jute, cotton, hemp, polypropylene ratfia, continuous polypropylene filament fabrics, or of other conventional backing material.
  • the backing is to be coated, it is advantageous to use as the coating material a polyolefin film of polyethylene, polypropylene, or the like.
  • a polyolefin film of polyethylene, polypropylene, or the like.
  • Such a film may be coupled to, e.g., laid upon, the backing before passing the whole through the oven. During passage through the oven the film is firmly anchored to the backing.
  • the coating substance (acrylic or polyvinyl resins, latex of natural or synthetic rubber, P.V.C. plastisol) may be applied to the manufactured article by total (dipping) or partial (coating of the back side) impregnation.
  • the fabric is then best heat treated, desirably in an oven preferably at from about to C. for a time period of from 5 to 20 min.
  • Dying of the fabrics may be carried out according to conventional techniques.
  • the chlorovinyl fibers used in the present invention show a variable heat shrinkage, depending upon the method used in their preparation and upon the possible materials admixed with the polymers.
  • the figure illustrates the shrinkage of chlorovinyl fibers suitable for the present invention.
  • the area within the hatched zone, shown by way of illustration, indicates preferred shrinking ranges for the chlorovinyl fibers.
  • Line 1 illustrates very highly shrinkable fibers (for instance, those sold under the trademark Movil N of the Italian Company Polymer S.p.A.);
  • line 2 illustrates much less shrinkable fibers (for instance, those sold under the trademark Movil T of Polymer S.p.A.).
  • thermo-shrinkable chlorovinyl fibers to be employed in the blend will depend upon the degree of shrinkage, in the sense that smaller quantities would be used in the blend when highly shrinkable fibers were employed, and higher amounts thereof would be used when low shrinkage fibers were employed.
  • the shrinkage of the non-woven fabric layer is also influenced by (1) the structure of the fabric particularly its thickness, (2) the characteristics of the backing, (4) the nature of the thermal treament (temperature and time) (3) the pinning treatment index (number of penetrations per surface unit 100-200 penetrations/cm.
  • pinning treatment index generally a smaller freedom of the chlorovinyl fibers and hence a smaller dimensional variability correspond to a more compact fabric.
  • the amount of shrinkage attained in accordance with the present invention is not necessarily as great as that illustrated in the figure. That is, inasmuch as there are constraints exerted upon the chlorovinyl fibers by virtue of their having been mechanically interlocked within the support, upon heating they are not free to shrink as much as they would want to in the absence of such constraints.
  • the amount of shrinkage is nevertheless sufiicient to achieve a firm effective fastening of the lap to the support.
  • the fibers suitable for use in this invention and referred to herein are well known. See, e.g., text by M. Sittig entitled Synthetic Fibers From Petroleum (1967) at pages 100-106 which describe polyamides, page 205 which describes polyester, pages 228-248 which describe acrylics, and pages 259-271 which describe polyolefins; the text by R. Hill entitled Fibers From Synthetic Polymers (1953); the text by F. Fourne entitled Synthetician Fasern (1964); the articles by E. Fricser, Textil-Rundschau 14, 1-6 (1959); and the article by R. W. Henerieff in Fibers, p. 113 (April 1957).
  • Example 1 was prepared consisting of:
  • polypropylene fibers modified by the addition of basic polycondensates of epichlorohydrin with at least one amine preferably with dicyclohexylesamethylenediamine and with piperazine (as described in the Belgian Pats. No. 591,201, No. 606,306 and No. 620,706) having a count of 17 d./tex (15 den.), and a staple length of 60 mm.;
  • the blend was transformed into a lap by passing it through a carding machine of the wool type.
  • the lap weighing about 700 g./m. was disposed over a fabric formed of jute fabric weighing 320 g./m.
  • the backing/lap composite was then passed through a conventional needle-punching machine undergoing 180 penetrations/omit Thereafter a polyvinyl chloride plas- 4 tisol was spread over the backing.
  • the fabric was then introduced into an oven at a temperature of 120 C. and kept there for about 12 minutes.
  • the fabric showed a very good anchorage of the lap to the backing. It was essentially non-inflammable and displayed a good abrasion resistance. In fact, the weight loss of 100 cm. of this fabric submitted to an abrader of the Cesconi type, after 3000 cycles under a 230' g./cm. load, amounted to only 1.05 g.
  • a comparison fabric having the same characteristics of the above lap weight (700 g./cm. of the above backing weight (320 g./cm.
  • Example 2.-A fiber blend was prepared consisting of:
  • nylon polyamide fibers polyhexamethylenadipamide
  • This fiber blend was transformed into a lap by passing it through a carding machine of the wool type.
  • the lap was arranged over a support of polypropylene ralfia. (See BritishPlastics, January 1966, pp. 38-39.)
  • This support was a woven backing having 6 filaments/cm., a count of 1000 d./tex in both the wrap yarn and the weft yarn.
  • the lap/backing composite was then passed through a needle-punching machine, undergoing 160 pen/cm. and through a total foulard impregnation in acrylic resins aqueous emulsion (the solid residue of the resin over the total weight of the article being 12% Thereafter the fabric was introduced into a heating oven at a temperature of 135 C. and kept there for about 8 minutes.
  • the fabric showed a good anchorage of the lap to the backing, and showed a good abrasion resistance.
  • Example 3 A blend of fibers was prepared consisting of:
  • the blend was transformed into a lap by passing it through a carding machine of the wool type.
  • the lap was then disposed over a backing made of a fabric of continuous polypropylene filaments, having a count of 1.00 d./tex and consisting of 70 filaments.
  • the lap/backing composite was then passed through a needle-punching machine and a polyvinyl chloride plastisol spreading as described in Example 1.
  • the fabric was then introduced into an oven at a term perature of 135 C. and kept there for about 10 minutes.
  • the fabric showed a good anchorage of the lap to the backing, and showed a good abrasion resistance.
  • Example 4.A blend was prepared consisting of:
  • the blend was transformed into a lap by passing through a carding machine of the wool type.
  • the lap was then disposed over a backing made of a fabric of continuous polypropylene filaments having a count of 1.100 d./tex and consisting of 70 filaments.
  • the composite was passed through a pinning machine (140 penetrations/cm?) foulard dipping with an acrylic emulsion bath in which the acrylic resin shows a solid residue of 15% over the total weight of said composite, and then introduced into an oven at a temperature of 125 C. and kept there for about 15 minutes.
  • the fabric showed, on testing with a Cesconi abrader under the same conditions of Example 1, a weight loss of 0.9 g.
  • Example 5 was prepared consisting of:
  • the blend was transformed into a lap by passing through a carding machine of the wool type.
  • the lap weighing about 500 g./rn. was then disposed over a backing consisting of a jute fabric (250 g./m.
  • the composite was then passed through a pinningrnachine 150 penetrations/cm?) and a dipping in foulard with an aqueous emulsion of an acrylic resin (250 g./cm.
  • the fabric was then introduced into an oven at 120 C. and kept there for minutes.
  • the sample according to the invention shows thus an abrasion resistance double than that of the comparison sample.
  • Example 6A blend was prepared consisting of:
  • the blend was transformed into a lap by passing through a carding machine of the wool type.
  • the lap weighing about 650 g./m. was then disposed over a backing made of continuous polypropylene yarns with a count of 1100 d./tex and 70 filaments; the weight of the backing was about 150 g./m.
  • the composite was passed through a needle punching machine (200 penetrations/cm. and spread on the back side with a butadiene-acrylonitrile latice containing thickeners, vulcanizing agents and mineral fillers in an amount suitable to give a solid residue of 1100 g./m. the article is then introduced in an oven at 135 C. during 15 minutes. Due to the good anchoring realized through the binding action of the shrinkable fibres, the upper part which is not impregnated with the latice, shows an abrasion resistance higher than that of a carpet made of 100% polypropylene fibres and totally impregnated (in foulard) with 270 g./cm. of solid residue of an acrylic resin.
  • the weight loss of cm. using the Cesconi abrader after 3,000 cycles with a 230 g./cm. load was of 1.05 g. for the carpet according to the invention and 1.5 g. for the comparative carpet.
  • thermo-shrinkable chlorovinyl fibers after the heat treatment (which follows the pinning), are anchored firmly to the backing, fixing thereto the other fibers of the lap.
  • the non-woven fabric when heated at C. for 8 minutes (in a tunnel dryer), was transformed into an article that showed a substantially black surface.
  • the white chlorovinyl fibers originally present in the surface layer, had shrunk because of the heat treatment and penetrated deeply the inner part of the non-woven fabric.
  • thermo-shrinkable chlorovinyl fibers in the blend (for the lap), which amount is dependent upon such factors as shrinking characteristics, quantity and color of the non-woven fabric forming fibers, etc. enable one to obtain a wide range of well proportioned colors having great esthetic appeal.
  • the said pinning-machine (or needle punching-machine or needle-loom) are well known in the art (see G. Robinson, Carpets, Pitman 1966; and also Technical Bulletin M6 of Monsanto, May 1967) and are exemplified by e.g. the Garnett Bywater, Hunter, Dilo, Fehrer needleoom.
  • the gist of this invention is in the provision of at least two different fibrous materials as components of the blend from which the lap is made. These different fibrous materials must be so selected that, upon heat treatment, differential shrinkage occurs therebetween.
  • differential shrinkage occurs therebetween.
  • the mechanical interlock between the lap and the support is such that tufts of the lap material extend all the way through the support.
  • tufts of the lap material extend all the way through the support.
  • the tufts of lap material extend all the way through the support. Thus, so long as these tufts penetrate the interior of the support, subsequent heating with the resultant differential shrinkage insures the formation of a mass or ball of material within the support, thereby anchoring the lap to the support.
  • a method of preparing a composite fabric comprising a non-woven lap secured to a fabric backing comprising, forming a fibrous lap composed of at least two components, one of said components being more heat shrinkable than the other, disposing said lap upon a fabric backing, needling said lap with said backing so that portions of said lap penetrate the interior of said backing to anchor said lap thereto, and heating to efiect differential shrinkage of said components, whereby said lap is more firmly anchored to said backing by virtue of the differential shrinkage of said components.
  • thermo-shrinkable chlorovinyl fibers contains from about 5 to by weight of thermo-shrinkable chlorovinyl fibers and correspondingly from about to 50% by weight of less thermo-shrinkable fibers.
  • thermoshrinkable fibers are selected from the group consisting of fibers of polyamides, acrylic fibers, polyester fibers, and polypropylene fibers.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
US719310A 1967-07-25 1968-04-08 Process for preparing non-woven fabrics Expired - Lifetime US3528147A (en)

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IT1876067 1967-07-25

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US (1) US3528147A (xx)
AT (1) AT303665B (xx)
BE (1) BE718527A (xx)
DE (1) DE1760917A1 (xx)
ES (1) ES356466A1 (xx)
FR (1) FR1596515A (xx)
GB (1) GB1182899A (xx)
IL (1) IL30398A0 (xx)
NL (1) NL6810174A (xx)
RO (1) RO61889A (xx)
YU (1) YU172968A (xx)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4446189A (en) * 1983-05-12 1984-05-01 Phillips Petroleum Company Textured nonwoven textile fabric laminate and process of making said
US4916782A (en) * 1987-12-14 1990-04-17 Armstrong World Industries, Inc. Method for making a non-woven flannel fabric

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2717190B1 (fr) * 1994-03-08 1997-11-07 Corbiere Sa Procédé pour la fabrication d'une étoffe double de fantaisie et étoffe double ainsi obtenue .

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2825958A (en) * 1953-05-28 1958-03-11 Du Pont Process for making woven felts
US3216082A (en) * 1962-12-11 1965-11-09 Dunlop Rubber Co Method of making shaped felt
US3235935A (en) * 1962-03-09 1966-02-22 Dunlop Rubber Co Method of making synthetic fibre felt
US3272898A (en) * 1965-06-11 1966-09-13 Du Pont Process for producing a nonwoven web
US3317335A (en) * 1963-03-04 1967-05-02 Ici Ltd Fibrous, non-woven sheet materials and the production thereof
GB1080222A (en) * 1964-02-06 1967-08-23 Ici Ltd Improvements in or relating to fibrous, non-woven,sheet materials
US3377231A (en) * 1964-06-11 1968-04-09 Kendall & Co Needled textile laminates and method for producing same
US3407461A (en) * 1966-11-29 1968-10-29 Monsanto Co Method for preparing nonwoven substrates

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2825958A (en) * 1953-05-28 1958-03-11 Du Pont Process for making woven felts
US3235935A (en) * 1962-03-09 1966-02-22 Dunlop Rubber Co Method of making synthetic fibre felt
US3216082A (en) * 1962-12-11 1965-11-09 Dunlop Rubber Co Method of making shaped felt
US3317335A (en) * 1963-03-04 1967-05-02 Ici Ltd Fibrous, non-woven sheet materials and the production thereof
GB1080222A (en) * 1964-02-06 1967-08-23 Ici Ltd Improvements in or relating to fibrous, non-woven,sheet materials
US3377231A (en) * 1964-06-11 1968-04-09 Kendall & Co Needled textile laminates and method for producing same
US3272898A (en) * 1965-06-11 1966-09-13 Du Pont Process for producing a nonwoven web
US3407461A (en) * 1966-11-29 1968-10-29 Monsanto Co Method for preparing nonwoven substrates

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4446189A (en) * 1983-05-12 1984-05-01 Phillips Petroleum Company Textured nonwoven textile fabric laminate and process of making said
US4916782A (en) * 1987-12-14 1990-04-17 Armstrong World Industries, Inc. Method for making a non-woven flannel fabric

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Publication number Publication date
NL6810174A (xx) 1969-01-28
YU172968A (en) 1974-10-31
IL30398A0 (en) 1968-09-26
ES356466A1 (es) 1970-01-16
DE1760917A1 (de) 1972-03-09
RO61889A (fr) 1977-10-15
AT303665B (de) 1972-12-11
BE718527A (xx) 1969-01-24
FR1596515A (xx) 1970-06-22
GB1182899A (en) 1970-03-04

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