Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
  • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
  • C09J123/04—Homopolymers or copolymers of ethene
  • C09J123/08—Copolymers of ethene
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
  • C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
  • C08L2666/14—Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• • 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]
  • Y10T428/31511—Of epoxy ether
• • 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]
  • Y10T428/31942—Of aldehyde or ketone condensation product
• • 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]

Definitions

• Nonwoven fibrous webs bonded with a crosslinked and partially neutralized ethylene/alpha, beta-ethylenically unsaturated carboxylic acid copolymer are provided which possess high tensile strength and stiffness without substantial loss of these properties after repeated washing or drycleaning.
• the copolymer comprises about 55 to 97 percent by weight ethylene and about 3 to 45 percent by weight of the alpha, beta-ethylenically unsaturated carboxylic acid (methacrylic acid), about 0 to 75 percent of the acid groups neutralized.
• Cross-linking of the copolymer occurs with about 1 to 25 percent by weight, based on the weight of copolymer, of an epoxy resin or an amino-formaldehyde resin preferably cured at 180 C. for 1 minute.
• the copolymer imparts the improved properties to the nonwoven web whereas the crosslinking resin gives durability.
• This invention relates to nonwoven fibrous webs bonded with a polymeric binder, and more particularly to nonwoven fibrous webs bonded with cross-linked ethylene/alpha, betaethylenically unsaturated carboxylic acid copolymers.
• Bonded nonwoven webs have advantages over woven webs for a large variety of uses. Bonded nonwoven webs have heretofore been formed by impregnating, printing or otherwise depositing an adhesive bonding material on a web predominantly comprising relatively long fibers, including those of textile length of from about one-half inch to about 2 inches, or more.
• the web of nonwoven fibers, to which the binder is applied can be produced inexpensively and with low capital investment by cording, garnetting, air-laying, papermaking procedures optionally followed by needle-punching procedures, or other known operations for which efficient automation is possible. The operation of bonding the fibers in place is much less expensive than conventional spinning and weaving.
• binders for nonwoven webs directed to these uses have been either polyvinyl acetate, butadiene/acrylonitrile, acrylic or styrene/butadiene emulsions.
• Each of these binder systems has distinct shortcomings concerning either their stifiness, tensile or binding properties after being washed and/or drycleaned. As a result, the completely successful use of nonwoven webs for these uses has not been realized.
• an article comprising: a nonwoven fibrous web and a binder for said web comprising a copolymer of about 55 to 97 percent by weight ethylene and about 3 to 45 percent by weight of an alpha, beta-ethylenically unsaturated carboxylic acid, about to 75 percent of acid groups neutralized with alkali metal ions, said copolymer cross-linked with about 1 to 25 percent by weight, based on the weight of copolymer, of an epoxy resin or an amino-formaldehyde resin.
• Nonwoven webs using the cross-linked copolymer as defined herein have very high tensile values both wet and dry before and after numerous cycles in conventional washing machines and also after drycleaning.
• any of the many techniques available for preparing nonwoven webs can be used in the present invention.
• such techniques involve laying down a mass of fibers (usually 0.5 to 3 inches long) by methods, such as cording, garnetting and air laying, and then entangling the fibers to a certain extent.
• fiber entangling can be accomplished by any method, needle punching is particularly suitable.
• needle punching is comparatively simple and an especially advantageous method of preparing nonwoven webs with any of a variety of thicknesses, porosities and densities.
• the nonwoven webs are prepared from natural or synthetic fibers, and preferably are composed of polyamide, polyester and acrylonitrile or blends thereof and with other natural and synthetic fibers.
• the polymeric binder applied to the nonwoven web to bind the fibers is applied as an aqueous dispersion.
• aqueous dispersions are described in copending application Ser. No. 745,956, filed July 19, 1968, in the names of Joseph Edward Reardon and Vernon Clare Wolff, Jr., now abandoned, and assigned to the assignee of the present application, the contents of which are'incorporated by reference.
• the dispersion contains 20 to 60 percent solids of an ethylene/alpha, beta-ethylenically unsaturated carboxylic acid copolymer, and epoxy resin or an amino-formaldehyde resin as cross-linking agent and a cross-linking catalyst.
• the copolymer comprises about 55 to 97 percent by weight ethylene, preferably 70 to percent; about 3 to 45 percent by weight of alpha, beta-ethylenically unsaturated carboxylic acid, preferably 5 to 30 percent of acrylic acid or methacrylic acid, with about 0 to 75 percent of the acid groups neutralized with alkali metal ions, preferably 10 to 50 percent neutralized with sodium from sodium hydroxide.
• the cross-linking agents are the amino-formaldehyde and epoxy resins generally known in the are and available commercially and are employed in the dispersion at levels between about 1 and 25 percent by weight, based on the weight of copolymer, and preferably at levels between 2.5 and 10 percent.
• Melamine-formaldehyde resin is the preferred crosslinking agent, and the best results are obtained with it present at a level of about 7.5 percent. Best results are obtained with epoxy resins at about 5.5 percent.
• the cross-linking catalyst is also present in the dispersion, and it is present at a level of about 1 to 25 percent by weight, based on the total weight of copolymer and cross-linking resin.
• TI-le catalyst used will depend on the cross-linking resin used, but, generally, an ammonium salt of an acid, such as an ammonium halide, is the preferred catalyst for the amino-formaldehyde cross-linking resin. Its preferred concentration is about 5 to 15 percent.
• a polybasic organic amine is present in the dispersion at approximately the same concentration as given above.
• the binder dispersion is applied to the web so as to impregnate or saturate it.
• the impregnated web is dried by passing the web through an air oven to evaporate the water and to cross-link the copolymer with the cross-linking resin.
• the catalyzed reaction cross-linking the epoxy resin and the partially neutralized ethylene copolymer once initiated by heat upon drying, will continue to react at room temperature due to the catalytic effect of the partially neutralized ethylene copolymer molecule.
• any temperature-time relationship can be employed which is sufficient to remove the water and cross-link the copolymer.
• heating temperatures are within the range of to 20 C. for a time within the range of 0.25 to 5 minutes.
• the dried and cured impregnated web will contain about 2 to 50 percent by weight of the cross-linked copolymer, preferably about 15 to 35 percent, based on the total weight of impregnated web.
• the dispersion contains 7.5 percent of cross-linking EXAMPLE l4 of 2 inches per minute on samples 6 inches long and 1 inches wide with a one-fourth inch notch midlength and perpendicular to the fabric. Wet tensile values were obtained after soaking the fabric for 1 minute in a 10 percent detergent solution (Mr. Clean) and then testing by the above method.
• the dura The dura;
• samples A and D hard inadequate cures due to insufficient times at temperature. Longer times at C. will give an adequate cure; however, for commercial economics, a cure of 180 C. for 1 minute appears to be optimum since longer times at 180 C. do not appreciably increase tensile properties.
• Example 1 The sample had a resin pickup of 36.39 percent a dry tensile EXAMPLES 15 TO 23 Example 1 was repeated except an epoxy resin (Genepoxy M-l95, a bisphenol A epichlorohydrin based resin sold by General Mills) and its curing catalysts were substituted for the melamine-formaldehyde resin and its curing catalyst. As in example 1, the percent of epoxy resin and percent of catalyst are based on the weight of copolymer. The results are shown in of 38.5 lbs/in. and a wet tensile of 40.5 lbs/in. before wash- 75 table 111.
• an epoxy resin Genepoxy M-l95, a bisphenol A epichlorohydrin based resin sold by General Mills
• the percent of epoxy resin and percent of catalyst are based on the weight of copolymer. The results are shown in of 38.5 lbs/in. and a wet tensile of 40.5 lbs/in. before wash- 75 table 111.
• the article of claim 2 wherein the copolymer comprises the water and cross link the copolymer about 70 to 95 Percent y Weight ethylenqandiabout 30 to 5 7.
• the process of claim 6 wherein the dispersion saturated Percent weight acrylic acid methacryhc acld, abou web is heated at a temperature within the range of l20 to 200 50 percent of the acid groups neutralized with alkali metal C and f a time within the range f0 25 to 5 minutes ions.
• the copolymer comprises 4.
• the article of claim 3 wherein the copolymer is crossabout 70 to 95 percent by weight ethylene and about 30 to 5 linked with a melamine-formaldehyde resin.
• nonwoven fibrous dispersion of a polymer binder and thereafter heating the web web is comprised of fibers, and is impregnated with 2 to to remove the water, the improvement comprising: (A) applypercent by weight of polymer, based on the total weight of the ing to the web an aqueous dispersion the solids of which comimpregnated web.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Nonwoven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Cited By (3)

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Citations (9)

• 1970
  • 1970-06-17 US US3622442D patent/US3622442A/en not_active Expired - Lifetime
  • 1970-08-20 BE BE755068D patent/BE755068A/xx unknown
  • 1970-08-20 CA CA091243A patent/CA929810A/en not_active Expired
  • 1970-08-20 NL NL7012330A patent/NL7012330A/xx unknown
  • 1970-08-20 FR FR7030650A patent/FR2059602A1/fr not_active Withdrawn
  • 1970-08-21 GB GB4048270A patent/GB1306129A/en not_active Expired
  • 1970-08-21 DE DE19702041661 patent/DE2041661A1/de active Pending

Patent Citations (9)

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