US3616167A - Staple fibre fabrics and method of making the same - Google Patents

Staple fibre fabrics and method of making the same Download PDF

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Publication number
US3616167A
US3616167A US17222A US3616167DA US3616167A US 3616167 A US3616167 A US 3616167A US 17222 A US17222 A US 17222A US 3616167D A US3616167D A US 3616167DA US 3616167 A US3616167 A US 3616167A
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United States
Prior art keywords
fibers
sheath
core
component
core component
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US17222A
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English (en)
Inventor
Raymond George Gosden
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Imperial Chemical Industries Ltd
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Imperial Chemical Industries 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
    • D04H1/54—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
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S57/00—Textiles: spinning, twisting, and twining
    • Y10S57/905—Bicomponent 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904—Staple length fiber
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material

Definitions

  • the present invention provides a yarn or textile fabriccontaining bicomponent staple fibers whereinthe staple fibers comprise two components existing in a sheath/corerelationship, the core component having a lower melting point than the sheath component, and the end portions 'ofthe fibers are bonded to other fibers in the yarn or fabric.
  • the yarn or fabric contains at least 50 percent by weight-of the bicomponent staple fibers and the said fibers contain at. least 25 percent by weight of the component forming the core.
  • Froni another aspect the invention provides a process for the manufacture of a yarn or textile fabric as defined above, forming a yarn or fabric'from the said bicomponent staple fibers, subjecting it to a heat treatment at a temperature above the melting point of the core component and below themelting point of the sheath component of the staple fibers to cause the said core component to softenand exude from the end portions thereof and contact adjacentfibers, and cooling the yarn or fabric to a temperature belowthe melting point of the core component.
  • the present invention is'of particular value when applied to knitted, woven or nonwoven fabrics formed from staple fibers which fabrics are normally liable to pilling.
  • pilling as applied to fabrics is well known, being the formation of smallballs of tangled fibers forming on the surface of fabrics during use. Filling is associated with fabrics containing staple fibers,-and our invention is especially applicable to fabrics containing a sufficiently high proportionof staple fibers of short lengths such that pilling is normally a problem.
  • the fabrics may, of course, be fabricated entirely from bicomponent sheath/core staple fibers. lf knitted or woven fabrics are to contain only a proportion of such bicomponent fibers, that proportion may be introduced in the form of yarn of mixed staple fibers oras a yarn of wholly bicomponent sheath/core staple fibers used together with a yarn of other composition, for example in a warp and weft relationship.
  • the core polymer is of a melting point sufficiently below that of the sheath so that itmaybeensured that the fabric may conveniently be exposed to thermal conditions which result in the core component being raised to a temperatureabove its melting point whilst at the same time temperature of the sheath component remains below its melting point and is substantially unaffected by the heating.
  • the duration of the thermal treatment need be no longer than that required to melt the core component and can be easily ascertained by simple tests.
  • Bonding is achieved at the end portions of the fibers and not at crossover points of fibers as with prior art bonding techniques, since when the fibers are heated to a temperature above the melting point of the core, the latter oozes out from the ends of the fiber which then bond onto adjacent fibers on cooling.
  • v I V The-fibers in a yarn maybe bonded by passing the yarn over a heated plate and fibers in a fabric may be bonded by treating the fabric in an air-oven.
  • a ny suitable combination of polymers may be employed as the sheath or core componentsprovided that there is good adhesion therebetween. Poor adhesion results in weak bonds being formed which may be readily broken and thereby reduce the effectiveness of the present invention.
  • Suitable combinations of polymers include, for example, polyethylene terephthalate, of melting point 260 and a copolyester of ethylene terephthalate and ethylene'iso'phthalate containing 60 ethylene terephthalate units to 140 ethylene isophthalate unitsin the molecule and having a melting point of 140 C.
  • Other suitable combinations include polyhexamethylene adipamide and a copolymer of polyhexamethylene adipamide and polyhexamethylene isophthalamide in a 7050 weight ratioand also poly hexamethylene adipamide and a copolymer of polyhexarnethylene adipamide and polyepsilon caprolactam in a weight ratio of 60:40.
  • the core may be located concentrically or eccentrically in the sheath.
  • EXAMPLE 1 mide in a weight ratio of 70:30 by melt-spinning in conventional equipment.
  • the tow is convened into a 3 d.p.f. Ila-inch staple fiber and spun into a 400-denier yarn on a Shirley Miniature Spinning Machine.
  • the spun yarn is passed continuously over a hot plate at 200 C. with a dwell time of seconds. Bonding of the fibers occurs between the cut end of one fiber andan adjacent fiber in the manner shown in FIG. A.
  • EXAMPLE 2 Three d.p.f. 4-6-inch crimped staple fibers, formed from bicomponent filaments in which the components exist in a sheath/core relationship, the sheath being polyhexamethylene adipamide and the core a copolymer' of polyhexamethylene adipamide and polyepsilon caprolactam in a 70:30 weight ratio (melting points 262 and 205C. respectivelyyandwhich bicomponent filaments have different core/sheath ratios, and 3 d.p.f. 4-6-inch polyhexamethylene adipamide staple fibers were spun to 2'fold/l8s worsted count, 6 t.p.i. singles twist and 3 t.p.i. doubles twist. Five yarns were spun from the following blends:
  • Samplesof yarn from each blend were knitted twofold on a iii-gauge hand flat bed knitting machine. Two' samples of each yarn were knitted, one being bonded in a hot air oven at 230 C. for 60 seconds, the other being used as a control sample. Fourbonc'led and unbonded fabric panels were examined for hairiness" afier mild abrading treatment. the degree of hairiness" being taken as an indication of the tendency of the fabric to Pill.”
  • Bonded fabric prepared from blends containing at least 50 percent bicomponent staple fibers were less hairy than the unbonded control samples, but below 50 percent there was no significant difference between the bonded and control samples.
  • Bonded fabrics formed from the bicomponent staple fibers having a core/sheath ratio of 30:70 were slightly less hairy than the unbonded control samples.
  • EXAMPLE 3 withdraw the fiber from the yarn recorded and compared with the force required to remove the fiber from a sample of unbonded yarn. The mean of 9 tests was taken.
  • EXAMPLE 4 Four d.p.f. 4-6-inch crimped sheath/core bicomponent staple fibers having, as the sheath component, polyethylene terephthalate (softening point 265 C.) and as the core component a polyethylene terephthalate/isophthalate (60:40, mole ratio) copolymer (softening point 140 C.) having a 50:50 and 75.25 (by weight) sheath/core ratios were spun on the worsted system to twofold 36s worsted count yarns. The yarns were woven across the warp of polyethylene terephthalate filament yarn in a 2:2, twill weave.
  • the fabrics were subjected to the "Atlas" pill test and examined after one hour, the degree of pilling being assessed subjectively against known standards (Standard 1 has excellent pilling resistanceStandard 3, poor).
  • the test results are 25/75 core/sheath 2 3 fered from that in the publication only in that the chamber was lined with cork one-eighth inch thick and the impeller rotated at l,080 revs/min.
  • EXAMPLE 5 Six d.p.f. bicomponent staple fibers of example 2 having a 50:50 core/sheath ratio were carded into a web and the web passed through a hot air oven at 230 C. at such a speed that the residence time in the oven was 60 seconds. immediately after leaving the oven the web was passed through the nip of a pair of cold calendar rolls. The resultant bonded nonwoven fabric had good drape and strength.
  • a textile article being a yarn or fabric containing bicomponent staple fibers wherein the said staple fibers comprise two components existing in a sheath/core relationship, the core component having a lower melting point than the sheath component and said article having been heat-treated to cause the core component of the staple fibers to exude from the ends thereof and bond the end portions of the fibers to other fibers in the yarn or fabric.
  • a textile article according to claim 1 comprising at least 50 percent by weight of bicomponent staple fibers.
  • bicomponent fibers are polyamide fibers and comprise, as a sheath component, polyhexamethylene adipamide and as the core component polyepsilon caprolactam in a :30 weight ratio.
  • a textile article according to claim 1 wherein the fibers are polyester fibers and comprise, as the sheath component, polyethylene terephthalate and as the core component, a copolymer of polyethylene terephthalate and polyethylene isophthalate in 40:60 mole ratio.
  • a process for the manufacture of a textile article from bicomponent staple fibers comprising forming the yarn or fabric from bicomponent staple fibers in which the components exist in a sheath/core relationship and the core component has a lower melting point than the sheath component, subjecting it to a heat treatment at a temperature above the melting point of the said core component and below the melting point of the said sheath component of the bicomponent staple fibers to cause the core component to soften and exude from the end portions thereof and contact adjacent fibers, and cooling the yarn or fabric to a temperature below the melting point of the core component.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Multicomponent Fibers (AREA)
  • Woven Fabrics (AREA)
US17222A 1969-03-12 1970-03-06 Staple fibre fabrics and method of making the same Expired - Lifetime US3616167A (en)

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GB1302269 1969-03-12

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DE (1) DE2011829A1 (pt)
GB (1) GB1234506A (pt)
ZA (1) ZA701587B (pt)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3828542A (en) * 1970-11-18 1974-08-13 Rhodiaceta Novel effect yarns and process for producing the same
US3874160A (en) * 1971-06-17 1975-04-01 Toray Industries Process for producing high bulky yarn by false-twisting system
US3877214A (en) * 1971-10-05 1975-04-15 Hollandse Signaalapparaten Bv Method for the manufacture of yarn
US3978267A (en) * 1970-05-20 1976-08-31 Imperial Chemical Industries Limited Compact twistless textile yarn comprising discontinuous fiber bonded by potentially adhesive composite fibers
US3993806A (en) * 1971-02-22 1976-11-23 Imperial Chemical Industries Limited Flocking non-woven fabrics
US4197156A (en) * 1976-05-08 1980-04-08 Chisso Corporation Apparatus for producing hollow-cylindrically shaped fibrous articles
US4526679A (en) * 1983-09-02 1985-07-02 Texaco Inc. Removal of low melting particles from unground coal liquefaction residue
US5284704A (en) * 1992-01-15 1994-02-08 American Felt & Filter Company Non-woven textile articles comprising bicomponent fibers and method of manufacture
US5845652A (en) * 1995-06-06 1998-12-08 Tseng; Mingchih M. Dental floss
US5904152A (en) * 1995-06-06 1999-05-18 Gillette Canada Inc. Dental floss
US6027592A (en) * 1995-06-06 2000-02-22 Gillette Canada Inc. Dental floss
US6293287B1 (en) 1996-09-13 2001-09-25 Gillette Canada Inc. UV-cured resin-coated dental floss
CN101784708B (zh) * 2007-08-22 2012-07-18 纳幕尔杜邦公司 由刚棒纤维和得自二氨基二苯砜的纤维的共混物制成的短纤纱和由其制得的织物和衣服以及它们的制备方法

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BG39917A1 (en) * 1982-10-29 1986-09-15 Bakhchevanov Method for manufacture of fabric
WO1989004886A1 (en) * 1987-11-25 1989-06-01 Maxwell Victor Lane Bonded fibrous insulation batt
GB2221477C (en) * 1988-08-31 2009-08-27 Philip John Poole Window blinds
DE4206997C2 (de) * 1992-03-05 1997-07-03 Milliken Europ Nv Verfahren zur Herstellung eines textilen Flachmaterials aus mindestens zwei Komponenten unterschiedlichen Schmelzpunktes
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5482772A (en) 1992-12-28 1996-01-09 Kimberly-Clark Corporation Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3978267A (en) * 1970-05-20 1976-08-31 Imperial Chemical Industries Limited Compact twistless textile yarn comprising discontinuous fiber bonded by potentially adhesive composite fibers
US3828542A (en) * 1970-11-18 1974-08-13 Rhodiaceta Novel effect yarns and process for producing the same
US3993806A (en) * 1971-02-22 1976-11-23 Imperial Chemical Industries Limited Flocking non-woven fabrics
US3874160A (en) * 1971-06-17 1975-04-01 Toray Industries Process for producing high bulky yarn by false-twisting system
US3877214A (en) * 1971-10-05 1975-04-15 Hollandse Signaalapparaten Bv Method for the manufacture of yarn
US4197156A (en) * 1976-05-08 1980-04-08 Chisso Corporation Apparatus for producing hollow-cylindrically shaped fibrous articles
US4526679A (en) * 1983-09-02 1985-07-02 Texaco Inc. Removal of low melting particles from unground coal liquefaction residue
US5284704A (en) * 1992-01-15 1994-02-08 American Felt & Filter Company Non-woven textile articles comprising bicomponent fibers and method of manufacture
US5845652A (en) * 1995-06-06 1998-12-08 Tseng; Mingchih M. Dental floss
US5904152A (en) * 1995-06-06 1999-05-18 Gillette Canada Inc. Dental floss
US6027592A (en) * 1995-06-06 2000-02-22 Gillette Canada Inc. Dental floss
US6293287B1 (en) 1996-09-13 2001-09-25 Gillette Canada Inc. UV-cured resin-coated dental floss
CN101784708B (zh) * 2007-08-22 2012-07-18 纳幕尔杜邦公司 由刚棒纤维和得自二氨基二苯砜的纤维的共混物制成的短纤纱和由其制得的织物和衣服以及它们的制备方法

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ZA701587B (en) 1971-10-27
DE2011829A1 (de) 1970-10-01
GB1234506A (pt) 1971-06-03

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