US3595731A - Bonded non-woven fibrous materials - Google Patents

Bonded non-woven fibrous materials Download PDF

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Publication number
US3595731A
US3595731A US752395A US3595731DA US3595731A US 3595731 A US3595731 A US 3595731A US 752395 A US752395 A US 752395A US 3595731D A US3595731D A US 3595731DA US 3595731 A US3595731 A US 3595731A
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fibres
web
sheet
adhesive
bonded
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Stanley Davies
Christopher Robert Sissons
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British Nylon Spinners Ltd
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British Nylon Spinners Ltd
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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
    • D04H1/485—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 weld-bonding
    • 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
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/549—Polyamides
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/55—Polyesters
    • 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
    • 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
    • D04H3/14—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 thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • 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
    • D04H3/16—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 thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • 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
    • D06N3/0031—Retractable fibres; Shrinking of fibres during manufacture
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24438—Artificial wood or leather grain surface
    • 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]
    • Y10T428/31725—Of polyamide
    • Y10T428/31728—Next to second layer of polyamide
    • Y10T428/31732—At least one layer is nylon type
    • 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]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/627—Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
    • Y10T442/629—Composite strand or fiber 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric

Definitions

  • non-Woven fibrous materials by incorporating, in the materials, fibres possessing the ability to crimp, twist or curl and subsequently causing the fibres to crimp, twist or curl by a suitable treatment such that they interlock and mechanically bond the material.
  • Such materials have advantages in terms of drape and handle over materials containing straight fibres and adhesively bonded materials but they are not sufiiciently Well bonded for many end uses and it has in many cases proved necessary to further adhesively bond the materials.
  • the components of the crimpable composite fibres are chosen so that at least one but not all of the components is potentially adhesive, that is can be rendered adhesive by a treatment which leaves the remainder of each fibre substantially unaffected, the component occupying at least a proportion of the peripheral surface of each fibre, and such fibres are used to form fibrous structures which are mechanically bonded by interlocking of crimped fibres and adhesively bonded, then the potentially adhesive components do not lose their fibrous form on being rendered adhesive under conditions such as to produce an adequately bonded structure.
  • the composite fibres may be prepared by the methods described in British Pats. Nos.: 579,081; 580,764; and 580,941 which involve co-spinning by a process of melt, plasticised melt, wet or dry spinning, the polymer materials so that they form a unitary filament.
  • Suitable processes and apparatuses for use in the production of composite fibres in which the components are in a side-by-side relationship by melt spinning, are, for example, described in British Pat. Nos. 953,379 and 1,035,908.
  • the composite fibres may be associated with other fibres or continuous filaments of almost any sort, the only substantial limitation being that those other fibres must not themselves be rendered adhesive by any treatment applied to develop crimp and/or to render adhesive the potentially adhesive components.
  • Wool, silk, flax, cotton, regenerated cellulose, mineral fibres including asbestos and sack wool, glass fibres, synthetic polymeric fibres, other composite fibres and the like are examples of such fibres which may in a particular instance be suitable.
  • such fibres are termed non-activatable fibres.
  • the fibrous structures containing the composite fibres may be utilised in numerous ways and the structures may take various forms depending upon the particular bonded textile material desired.
  • the composite fibres either alone or in admixture with non-activatable fibres may be carded and then subjected to drafting and spinning to produce a yarn.
  • the yarn after it has been woven or knitted is then treated to develop crimp and render adhesive the potentially adhesive component, the treatment serving to stabilize both the structure of the yarns within the fabric and the structure of the fabric as a whole by adhesion of fibres at points of intercrossing of the yarns.
  • the composite fibres containing a potentially adhesive component may be fabricated into cards by plying, after which the plies may be bonded together.
  • the yarns may be formed by continuous filaments some or all of which are composite fibres and such yarns may be formed into woven or knitted or plied structures in the same manner as a staple fibre yarn.
  • Yarns consisting of or containing composite fibres may be utilised in the manufacture of laid or woven scrims which are employed, for example, for the reinforcement of sheets of plastic.
  • the use of composite fibres in the manufacture of scrims greatly simplifies the operation since bonding can be accomplished simply by the applica tion of heat and pressure and thus the necessity for using a heat resistive warp size or dipping the structure in an adhesive before bonding on the loom is eliminated.
  • fibrous structures in the form of fibrous Webs are employed in the production of non-woven fabrics.
  • the fibres are formed into a Web of convenient thickness by a variety of methods, the method selected in a particular instance, depending to a very large extent on the length of the fibres when fibres other than continuous filaments are used.
  • Staple fibre webs may be prepared, for example, by a woollen or cotton carding machine or a garnetting ma chine which result in a web in which the staple fibres are oriented predominately in one direction.
  • the thin web obtained from a single card or garnet may be used by itself but generally it is necessary and desirable to superimpose a plurality of such webs to build up the web to a sufficient thickness and uniformity for the end use intended.
  • alternate layers of carded webs may be disposed with their fibre orientation directions disposed at a certain angle, conveniently with respect to intervening layers.
  • Such cross-laid webs have the advantage of possessing approximately the same strength in at least two directions. Furthermore cross lapping in this manner provides a product having a balanced stretchability.
  • a stationary formed screen may be used for the formation of shaped articles.
  • it may take the form of a hatshaped cone such as is used in the hatting trade.
  • it may have any other form suitable for producing the desired shape of the bonded-web nonwoven products of this invention.
  • a method of making a web containing fibres of a shorter length, say 0.5 inch or shorter, involves a wet laying technique such as use of a Fourdrinier or other paper-making machine.
  • Compaction of the bonded Web can be effected, for instance by pressing between rolls or plates and preferably pressures of at least 20 lbs. per square inch are utilised in order to obtain useful leatherlike materials.
  • pressures of at least 20 lbs. per square inch are utilised in order to obtain useful leatherlike materials.
  • press the web between rolls or plates at least one of which is heated With such heating it is possible once again to produce products having uniform or non-uniform densities and to produce products of low density in the centre and high density in the surface layers.
  • the non-compacted non-wcven products of the present invention have densities in the range from 0.01 to 0.08 gms./cm. porosities of at least 75 percent and tensile strength to density ratios of at least 200 and the compacted non-woven products of the present invention have densities of at least 0.08 gm./cm. and a tensile strength of at least kg./gm./cm.
  • the non-woven products of the present invention are useful in many diversified fields such as insulating interlinings, apparel fabrics, brassiere pads, helmet liners, hat bodies, sleeping bags, pillows, blankets, bedspreads, crash pads, surgical pads, carpet underlays, fillers, upholstery, luggage, handbags and also find use in laminates.
  • FIG. 1 shows diagrammatically, by way of example, in perspective, an apparatus useful for making a sheet-like article according to this invention by a continuous process
  • FIG. 2 shows a schematic representation of a fibrous web formed by a part of the apparatus of FIG. 1 and subsequently treated to give a sheet-like article according to this invention
  • FIG. 3 is a photograph, i.e representation on an enlarged scale (x10) of a section of the sheet-like article of Example 1;
  • FIG. 4 is a photograph, i.e. representation on an enlarged scale (X10) of a section of the sheet-like article of Example 9;
  • FIG. 6 is a diagrammatic representation, in perspective, of a laminated article provided by this invention.
  • FIG. 7 is a cross-sectional elevation along the line VlI-VII of the laminated article of FIG. 6.
  • sheet material may be prepared by forming a fibrous web of continuous monofilaments, for example, heterofilaments, by drawing such filaments 11 off a number of bobbins (not shown) or like storage device for filaments already spun, and then forwarding the filaments between two feed rolls 12 having fluted surfaces onto a Wire mesh conveyor belt 14.
  • the rate of deposition of the filaments onto the conveyor belt 14 is faster than the speed of the belt as a result of which the filaments are disposed in the fibrous web 13 in a random configuration without parallelism between individual filaments as is more clearly brought out in FIG. 2 described hereinafter.
  • the fibrous web 13 after deposition on the belt is carried through oven 15, in which the filamentary material is crimped and bonded by heating to a suitable temperature.
  • Rolls 16 lightly grip the resultant sheet material and forward it to a collection point at 17.
  • the continuous filaments may be deposited directly onto the belt to form the web by means of jet devices.
  • FIG. 2 of the accompanying drawings The random dispersed arrangement of the continuous filaments making up the fibrous web 13 of FIG. 1 is illustrated diagrammatically in FIG. 2 of the accompanying drawings.
  • the randomness of the filaments 11 of which the web is composed can be ascertained by examining square samples such as the one indicated at A. Such a sample, regardless of where in the sheet it is taken, has substantially'the same number of filaments crossing each side of the square.
  • the non-woven products of this invention and the process for manufacturing the same will now be more clearly illustrated in the following examples which are not to be regarded as limitative of the invention.
  • the tensile strength of the products is determined on a 6 inch long and two inch wide strip employing an Instron Tensile Tester the jaws of which were set cms. apart.
  • tensile strength is determined at room temperature under ambient conditions of 60 percent relative humidity and a rate of elongation of 5 cm./minute i.e. 100 percent.
  • EXAMPLE 1 This example illustrates the formation of a sheet-like article consisting of 100% composite fibres.
  • EXAMPLE 7 A quantity of the staple fibre of Example 6 was carded using a Shirley miniature carder and the laps so formed cross-laid to give a web having a weight of 5 ounces per square yard and a density of 0.01 gm./cm. A portion of the cross-laid web 6 /2 inches long and 6 inches wide was immersed in a formaldehyde/ glycerol mixture at a temperature of C. for a period of 15 minutes.
  • EXAMPLE 9 This example illustrates formation of a bonded web non-woven product in sheet form from a wet-laid web.
  • the resulting sheet-like article had a feel very similar in certain respects to sponge or a foam rubber but differ ent therefrom in having a uniform elasticity and strength in all directions in the plane of the sheet. It had the appearance of a closely matted mass of fine fibres distributed more or less randomly throughout the structure with the fibres bonded together at cross-over and contact points. The product was also distinguishable from a foam rubber in that it was air and liquid permeable and had a higher tear strength.
  • non-woven products of this invention may be in the form of shaped articles other than hat bodies. These may be produced, for example, by shaping a sheet immediately after fibres of the web are bonded together and before the sheet has cooled into the required shape, which shape they retain on cooling.
  • short sections of pipe may be covered with a layer of insulating material by wrapping the hot sheet about the pipe until a layer of requisite thickness has been built up, and then allowing the structure to cool. Such wrapping can be effected without extensive rupture of the bonds between the fibres and without excessive compacting of the sheet, which thereby largely retains its bulky characteristics with numerous small air spaces and high insulating value.
  • EXAMPLE 15 A quantity of 12 denier, two and a quarter inch staple fibre formed from a fully drawn potentially crimpable polyhexamethylene adipamide/poly( omega-aminoundecanoic acid (nylon 66/11) composite fibres in which the two components are present in equal proportions by weight and in a side-by-side relationship, having a slight helical crimp caused by the drawing process, was carded using a carder into a Web 2.5 cm. thick, having a density of 0.01 gm./cm. This web was then heated in an air oven at a temperature of 230235 C.
  • the bonded web was compacted between two calender rolls which exerted a pressure of approximately 120 pounds per square inch on the bonded web.
  • the sheet which contained deformed crimped fibres which could be seen when a portion of the sheet was examined under a microscope, had a useful flexibility and did not crack on repeated bending.
  • the surface of the material could be raised and the material given the general appearance and feel of suede leather by passing the compacted sheet through a sueding calender, in which the surface of the sheet come in contact with a roller coated with emery powder and revolving at 1500 revolutions per minute.
  • the material itself was a useful leather-replacement but we find that for some application it was advantageous to apply to one or both surfaces of the sheet a suitable coat.
  • the coat has a thickness of between 2 to 4 mils.
  • Polyurethanes make excellent coating materials and the composite structures so formed are particularly useful in the upholstery art.
  • EXAMPLE 17 A quantity of the staple fibres of Example 15 was blended with a quantity of non-activatable stulfer-box crimped polyhexamethylene adipamide 1 /2 inch 6 denier per filament staple fibre in a 60/40 ratio by Weight. A portion of this blend was carded using a Shirley miniature carder into a loose Web 1.3 cm. thick, having an average density 0.02 gm./cm. The web was heated in an oven for 4 minutes at a temperature of 220-232 C. and under an initial pressure of 0.05 gm./cm. to give the resulting product a smooth surface. As the fibres attained the ambient oven temperature, by which time the composite fibres were substantially fully crimped the lower melting component of the composite fibres i.e.
  • the bonded web within seconds of its removal from the air oven was pressed between a flat metal plate and a rubber pad for a period of about 1 to 2 minutes, to produce a compact, porous structure containing deformed crimped fibres.
  • the resulting sheet had a leather-like appearance and general feel, but it was in addition more soft and supple and the smooth surface had better crease resisting qualities than the material made according to Example 15.
  • the bonded web was pressed between two flat chip boards the applied pressure being approximately 85 pounds per square inch; in consequence of the application of compaction pressure in this manner, crimped fibres of the bonded web were deformed and a compact, porous sheet structure produced.
  • the sheet had a density of 0.24 gm./cm. a weight per unit length of 0.043 gm./cm., an extension to break of 9 percent, a tensile strength in kg./gm./cm. of 184 and a porosity of 14 cc./sec./ cm.
  • EXAMPLE vl9 A non-woven carded web as in Example 17 but composed of 20 percent by weight of the composite fibres and 80 percent by weight of the non-activatable stulfer-box crimped polyhexarnethylene adipamide fibres (3 denier per filament) was allowed to shrink freely in all directions whilst being heated in hot air at a temperature of 240 to 255 C. for a period of 4 /2 minutes at which temperature the poly (omega-aminoundecanoic acid) component of the heterofilament was activated i.e. developed its adhesive characteristics, thereby fusing together composite fibres in contact with one another and with the non-activatable fibres.
  • the poly (omega-aminoundecanoic acid) component of the heterofilament was activated i.e. developed its adhesive characteristics, thereby fusing together composite fibres in contact with one another and with the non-activatable fibres.
  • the area shrinkage was about 12 percent and the resulting sheet had an average density of 0.020 gm./cm.
  • the sheet had a very open structure, and was extremely flexible there being little evidence of windowpaning (i.e. there was preservation of substantially all the interstitial spaces) and could be crumpled and folded and then spread out flat in its original state.
  • the sheet had a homogeneous structure, in the sense, that it consisted entirely of fibres all of which were selected from the same chemical classification i.e. all fibres had the same functional groups, it was readily dyed uniformly with only one dyestuff.
  • the sheet of this example could be dyed with an acid type dyestutf used for polyamide dyeings to a uniform and even shade, the resulting flexible structure with a useful ability to breathe being useful for upholstery purposes.
  • the material was easily embossed to give a sharp and permanent pattern by pressing the surface with a patterned heating embossing plate.
  • the bonded web was then compacted between two flat blocks of wood exerting a pressure approximately 150 pounds per square inch on the bonded web. The pressure was maintained for about 3 minutes.
  • the compacted sheet structure may be treated by any of the usual processes employed to treat and finish leather.
  • Pigmented and plasticised polyvinyl chloride compositions could be applied as surface coatings to the above described sheet material to produce a good quality upholstery material.
  • the web instead of pressing the bonded-web immediately after its removal from the nitric acid, the web, after the nitric acid treatment, may be washed with hot water to remove the nitric acid and thereafter allowed to stand for several minutes at room temperature. At the end of this period substantially all the potentially adhesive component was no longer in a tacky condition.
  • a leatherlike material could be obtained from the cold, bonded-web by hot-pressing it for three minutes at a temperature of -150 C. and a pressure of about 200 pounds per square inch. Under these conditions of heating and pressing the potentially adhesive component, at least that which 21 lies at or near to the surface of the sheet, is reactivated and this re-activation enables the crimped filaments to be deformed under the compacting pressure.
  • EXAMPLE 22 This example illustrates the formation of shaped articles consisting of the leather-like materials of this invention.
  • Example 15 A quantity of the staple fibre used in Example 15 was carded using a Shirley miniature carder and the laps so formed cross-laid in a conventional manner into a strip of a loose layered web having a thickness of about 2 inches and a basic weight of 5 ounces per square yard. The web was then heated in an air oven for a period of 3 minutes at a temperature of 220240 C.
  • a hat-shaped article may be produced by compacting a bonded-web formed on a hat mould.
  • the bonded-web was formed in the mould by crimping and activating a fibrous web air-deposited there- EXAMPLE 23
  • a quantity of the staple fibres used in Example was carded using a Shirley miniature carder and the laps so formed cross-laid to provide a layered web having a basic weight of 8 ounces per square yard.
  • a portion of this web was heated in an air-oven for a period of 3 /2 minutes at a temperature of 230-240 C., under an initial pressure of 0.16 gm./cm. provided by a mica sheet.
  • the bonded-web which resulted from this treatment was removed from the oven allowed to stand at room temperature for thirty seconds. Thereafter, the bonded-web was compacted between two flat plates which exerted a pressure of about 130 pounds per square inch on the web.
  • the effect of allowing an interval of thirty seconds to elapse between the termination of the bonding treatment and the compaction stage was to produce a material which had a very dense and compact central portion and relatively less dense surfaces.
  • the sheet had, as a result, a heterogeneous structure. This effect finds an explanation in the fact that, as a result of the delay prior to compaction, the potentially adhesive component at and close to the surface of the bonded-web was no longer tacky.
  • the sheet had a basic weight of 14 ounces per square yard, an extension to break of 54 percent and a tensile strength of 222 kg./ gm./ cm.
  • a bonded fibrous material comprising at least five percent, based on the Weight of fibres in the material, of crimped composite fibres comprising at least two fibreforming synthetic polymeric components arranged in distinct zones across the cross-section of each fibre, each component being continuous along the length of each fibre and at least one, but less than all, of the components being potentially adhesive and located so as to form at least a portion of the peripheral surface of each fibre, said crimp being derived from difierent physical properties of the components, the fibres of the material being entangled with each other due to said crimp and being bonded to each other where they are in contiguous relationship by the adhesive characteristics of said potentially adhesive component whereby the material is strengthened and stabilised.
  • a bonded fibrous material as claimed in claim 1 which comprises a non-woven product having a density 22 in the range from 0.01 to 0.08 gm./cm. a porosity of at least percent and a tensile strength to density ratio of at least 200.
  • a bonded fibrous material as claimed in claim 1 wherein the potentially adhesive components is poly- (omega-aminoundecanoic acid).
  • a process for making bonded fiberous materials which comprises forming a fibrous structure containing at least five percent, based on the weight of fibres in the assembly, of composite fibers comprising at least two fibreforming synthetic polymeric components arranged in distinct zones across the cross-section of each fibre, each component being continuous along the length of each fibre and at least one, but less than all, of the components being potentially adhesive and located so as to form at least a proportion of the peripheral surface of each fibre, said composite fibres possessing latent crimp due to different physical properties of the components, developing crimp in said fibres in the absence of any appreciable pressure to entangle them with each other, rendering the potentially adhesive component adhesive and bonding the fibres to each other where they are in contiguous relationship by the adhesive chaarcteristics of said component.
  • a process for making bonded fibrous materials as claimed in claim 12 wherein the crimped, bonded structure is subsequently compacted to deform the crimped composite fibres and at least a proportion of the assem bly is set in its compacted state.
  • a process as claimed in claim 17 in which the chemical treatment comprises contacting the fibrous structure with a non-aqueous solution of formaldehyde.
  • a process as claimed in claim 17 in which the chemical treatment comprises contacting the fibrous structure with a nitric acid solution.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US752395A 1963-02-05 1968-08-13 Bonded non-woven fibrous materials Expired - Lifetime US3595731A (en)

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FR1392034A (fr) 1965-03-12
CH514013A (de) 1971-11-30
DE1560653B1 (de) 1971-12-16
BE643420A (ja) 1964-08-05
FI44052B (ja) 1971-04-30
SE327688B (ja) 1970-08-31
NO124547B (ja) 1972-05-02
ES296121A1 (es) 1964-08-16
LU45367A1 (ja) 1964-04-14
GB1073183A (en) 1967-06-21
LU45363A1 (ja) 1964-04-06
GB1073181A (en) 1967-06-21
DK120531B (da) 1971-06-14
ES296120A1 (es) 1964-07-16
AT291922B (de) 1971-08-10
AT296211B (de) 1972-02-10
DK116125B (da) 1969-12-15
FR1392035A (fr) 1965-03-12
CH448006A (de) 1967-12-15
SE327687B (ja) 1970-08-31
NL6400929A (ja) 1964-08-06
FI44052C (fi) 1971-08-10
NL6400932A (ja) 1964-08-06
CH135564A4 (ja) 1967-10-31
BE643421A (ja) 1964-08-05

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