Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • 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
  • D06N3/0009—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 knitted fabrics

Definitions

• ABSTRACT Coated textiles are produced by a process in which 4-rail [52] U.S. Cl ..l17/37, 26/29, 28/74, knitted fabric which i napped on one face is coated on the 7/11, 7/411 7 7/109! 7/161 KP napped face with a polyurethane and subsequently grained [51 Int. Cl ..B44d 1/44 mechanically [58] Field ofSearch ..l6l/67; 28/74; 26/29; 117/1 1,
• This invention relates to coated textiles and to a process for producing the same. More particularly, this invention relates to textiles coated with polyurethane and to a method of producing the same.
• Another object of this invention is to provide coated textiles and a process for producing the same which is devoid of the foregoing problems and disadvantages.
• Another object of this invention is to provide coated textile material that is of such a construction that it can be acceptably coated by both the direct coating process and the reverse coating process.
• a further object of this invention is to provide a coated textile and a process for producing the same wherein a coated knitted fabric having a grain which is irregular and which can be as varied as desired and yet which does not repeat itself periodically is obtained.
• a still further object of this invention is to provide such coated textile fabric grained by mechanical means.
• Yet another object of this invention is to provide coated textiles and a process for producing the same wherein said coated textiles have a substantially constant weight per unit area over large production lengths.
• a process for producing coated textiles utilizing as the starting material a knitted fabric which is stable under tension and which is made of a pattern that can be napped and which comprises tearing open the threads of the knitted fabric introduced on the upper guide bar (rough laying) during the napping process and then coating the fabric with a polyurethane coating composition.
• a suitable starting material for this purpose is 4-rail warped knitted material in which the fiber pile produced by the napping process is of such uniformity that no subsequent shearing of the napped product is required. in the 4-rail construction the knitted material produced in this manner is so stable in the uncoated state that it can be conveniently washed and dyed on ajig.
• a particularly preferred form of this invention relates to a process for the production of textiles which are coated with polyurethanes by a process in which a 4-rail knitted fabric which has been napped on one side is coated on the napped face with a polyurethane coating composition and is subsequently grained by mechanical means.
• the invention also produces in this preferred form a coated textile of 4-rail warp knitted material which is napped on one side and coated on the napped face with a polyurethane coating composition and subsequently grained mechanically.
• the knitted fabrics to be used in the process according to the invention can be produced from one or more fibers of known types. Both non-twisted and twisted or folded yarns as well as endless filaments can be used. Mixed fiber constructions can be produced, for example, by supplying the four rails with fibers of different origin.
• Suitable fibers are, for example, those obtained from polyamides such as polyamide-6 from caprolactam, polyamide-66 from adipic acid and hexamethylene diamine, or polyamide-l2 and the like, terephthalic acid polyesters such as, for example, polyethylene terephthalate, polyacrylonitrile, cellulose-2 /2- acetate, cellulose triacetate, cotton, wool, rayon, regenerated cellulose, polyolefins such as polyethylene, polypropylene and the like, vinyl derivatives such as polyvinyl chloride, polyvinylidene chloride and the like, and polyurethanes.
• polyamides such as polyamide-6 from caprolactam
• polyamide-66 from adipic acid and hexamethylene diamine
• polyamide-l2 and the like terephthalic acid polyesters such as, for example, polyethylene terephthalate, polyacrylonitrile, cellulose-2 /2- acetate, cellulose triacetate, cotton, wool,
• the fibers may be pure white, matted or spun dyed. They can be colored by the usual dyeing and printing processes employed in the textile industry.
• the knitting data that is, for example, the warp thread count, pattern, stitch count, rod count or guide rails may, of course, be varied and be of any suitable parameter. These knitted materials can be coated in the napped state both on the napped surface and on the smooth surface by the usual processes generally known to those skilled in the art.
• Knitting of a stable knitted fabric for example, on a 4-rail warp knitting loom;
• Napping the goods such as, for example, on a hosiery napping machine with 24 rollers, on a napping machine for woven fabric with 32 rollers, or on any other suitable roller scraper napping machines which have both stroke and counterstroke rollers;
• the coating apparatuses should be suitable both for use in the direct coating process and in the reverse coating process.
• Steps 4 and 5 may be omitted in the case of spun dyed or predyed yarn or filaments. The individual steps are described in more detail below.
• Knitting A stretch resistant or dimensionally stable warp knitted fabric, for example, made of a 4-rail construction, is suitable for use in production of a stable basic fabric which is substantially equivalent to a woven fabric as regards resistance to stretching in width wise and length wise.
• Width of untreated material about I80 cm.
• the 4-rail warp knitted goods knitted according to these data have a final weight per square meter (prior to coating) of about 230 to about 240 go, it has been found in practice that such a weight per square meter is very suitable for textile purposes.
• the weight per square meter may, however, be varied within wide limits.
• 40, 60, 80, 100 or 120 and the like den cuprammonium rayon filaments may be used in the upper guide bar (rough patterning) or alternations may be effected by altering, for example, the feed ratio, the stitch count and rod count and the pattern. Changes in the stability of the fabric can be produced, for example, by supplying all the guide bars with nylon-6 or nylon-66 or other fibers in contrast to that used in the above-mentioned examples.
• the guide bars may also be supplied with the same or different fibers or filamentary materials as previously disclosed.
• Warp knitted goods which are strong or dimensionally stable, made, for example, from a 4--rail construction, have certain advantages Over woven goods. Spinning and variations in the material are eliminated since one can always work with the same den or dtex numbers on capillary numbers and the same stitch count, rod count, pattern, feed ratio and the like. Furthermore, it is much easier to produce a certain weight per square meter within narrow tolerances.
• Heat fixing When using synthetic fibers, especially of the polyamide type, a heat fixing step may have to be employed which may be carried out in the usual manner on suitable tentering frames. Accurate control of the temperature, keeping it constant, is especially important.
• Dyeing may also be carried out on the rear face ofthe white raw material.
• Suitable dyeing apparatuses are, for example, jigs, and HT beam dyeing apparatuses and the like.
• Napping Napping of the knitted goods to be used according to the invention can be carried out without any significant shrinkage in width, for example, on a 24 roller hosiery napping machine, or, for example, on a 32 roller napping machine for woven goods. Four to six passages through such machines are generally necessary to achieve sufficient napping. This is an important advantage over the process of napping woven fabric to achieve a more or less comparable effect since, for example, duvetyn, moleskin or velvetone require about 30 to passages through napping machines to obtain a suitable quality fabric. Owing to the fact that the fiber floats are always the same in the guide bar 4 (rough laying) napping is easier to achieve and no subsequent or intermediate shearing is necessary. These shearing processes are unavoidable when achieving a uniform pile in woven goods. Another advantage is that, in contrast to comparable woven napped fabric, napped knitted fabric need not be dampened or brushed.
• Napping of the fabric is generally carried out in the direction of the pile but may also be carried out against the pile, according to the napping system or types of napping machines employed.
• the process is started at a low napping 0 energy and this is gradually increased during the subsequent passages through the machine. It has been found to be desirable that, for example, the 4-rail warp knitted goods does not undergo any increase in density on napping owing to mechanical shrinkage in width and that the floats placed in the guide bar 4 can be napped completely and uniformly in the napping machine with practically no shrinkage in width. This effect is especially advantageous in allowing one to obtain constant weights per square meter over large production lengths.
• Felt calendering should be used to obtain a satisfactory handie in the case ofa uniform compacted surface. Calendering is carried out in the direction of the pile. The temperature may, for example, be from about C. to about C., and the pile face is placed on steel and the rear face on cotton. Other equipment, such as, for example, cylinder presses or smoothing calenders, are also suitable.
• Various processes can be employed for coating the fabric. in the direct coating process, for example, one can use a transparent undercoat followed by a pigmented filling or top coat.
• the fabric may first be provided with a transparent undercoat and a pigmented top coat is then applied by the reverse coating method.
• the fabric can be directly provided with a pigmented top coat by the process ofreverse coating without the use ofan undercoat.
• the transparent undercoat is applied by the reverse process and after the reaction is complete, the surface is coated by the direct process with pigmented solution of high molecular weight compounds.
• the above-mentioned transparent coats consist of polyurethanes which may be prepared, for example, from higher molecular weight polyhydroxyl compounds such a hydroxyl polyesters, polyethers, polyester amides or polyacetals and the like, preferably polyhydroxyl polyesterurethanes, such as, for example, those disclosed in German Pat. Nos. 1,012,456; 957,294; 897,625; and 847,502, and polyisocyanates. Suitable polyisocyanates are those disclosed, for example in German Pat. Nos. 957,294; 1,012,456; 870,400; 953,012 and 1,090,196.
• the polyurethanes which are to be used according to the invention adhere very firmly on the textile substrates.
• the transparent undercoating can be produced from a combination of the following components;
• a solution of a basic accelerator which consists of the following individual components; 7 parts of phenyl diurethane 3 parts of tetraoctadecyl titanate 45 parts of ethylene chloride 45 parts of ethyl acetate 2 parts of acetic acid 025 parts of acetic acid anhydride.
• the additive c) is not necessary if a transparent undercoat is applied to the direct process and this is followed by reverse coating.
• an undercoat having a composition in which, for example, as component a) 1,000 parts of a 30 percent solution of a polyesterurethane prepolymer (polyester of adipic acid and hexane diol prelengthened with toluylene diisocyanate) in acetic acid ester is reacted with 50 parts of a component analogous to b) and 50 parts ofa component analogous to c) are used.
• a polyesterurethane prepolymer polyester of adipic acid and hexane diol prelengthened with toluylene diisocyanate
• An undercoat can also be prepared, for example, by reacting 1,000 parts of a 30 percent solution of polyesterurethane prepolymer (polyester of adipic acid and diethylene glycol pre-lengthened with toluylene diisocyanate) with 50 parts of a component analogous to b) and adding 50 parts of a component analogous to c).
• the pigmented coating may, for example be a paste of 600 parts of 30 percent polyesterurethane prepolymer solution in ethyl acetate, 35 parts of a solution analogous to b) and 35 parts of a solution analogous to c) in which 30 parts of a silicic sol which has a very large surface area, 80 parts ofa titanium dioxide pigment of the rutile type, 3 parts of a green chromium oxide pigment and 1 part of a brown iron oxide pigment have been ground in. An ivory color is thereby obtained.
• a deep red coating is obtained, for example, by adding 35 parts of a cadmium red pigment to the above-mentioned pigment containing composition.
• the single colored coating can easily be made more decorative by applying certain color effects. This can be done, for example, by any suitable known roller printing or film techniques. Ornamental effects can also be obtained by spraying the fabric with differently colored solutions of high molecular weight compounds or dyes. It is also known that pre-printed ornaments on special supports may be applied to the coating in the manner of transfers. Furthermore, when using grained transfer paper, one may employ an undercoat which is of a different color to the top coat.
• Finish A finish is generally applied in order to obtain an elegant smooth flowing handle. Silicone products are particularly suitable for this purpose in the case of textile materials which are to be used for clothing. A finish can be applied by means of doctor blades, spraying or by immersion in a bath of the finish. Finishes comprising, for example, cellulose acetobutyrate or mixed esters of ethyl and methyl silicic acid are preferably used in the production of upholstery articles. The finish should not be applied until the coated fabric has been cross-linked to such an extent that it can easily withstand being rolled out.
• the fabric is treated for this purpose in an axial spin drier the direction of rotation of which can be altered as desired.
• Machines of this type are known as tumblers.
• the fineness of the grain can also be influenced by this method.
• the treatment temperature is generally between about 20 C. and about C., preferably about 50 C. to about 70 C.
• the periods of residence in the tumbler are generally between about 3 and about 10 minutes. The higher the treatment temperature, the shorter will be the required period of residence and the finer will be the grain.
• the felt calendering carried out in the previous stage and the application of the coating in the case of the reverse process coating also have an important effect on the final nature of the grain.
• the axial spin drier should have a drum diameter of at least about em but preferably more.
• the fabric should first be provided with a suitable finish to prevent the fabrics sticking when applying the grain.
• the coated fabric should be allowed to stand for about 24 to about 28 hours before graining to avoid formation of surface cracks. Different but reproducible grain effects can be achieved in this way.
• the fabric may subsequently be stretched with slight dampening and at the same time rolled up to remove creasing in the grained fabric.
• the products obtained according to the invention may be used, for example, for clothing, millinery material, upholstery materials, protective coverings, household textiles, bags and luggage, decorative material and material for wood facings.
• the materials may be worked up by the methods normally employed in the art, for example, they may be backed with foam plastics and provided with decorative quilted seams.
• the material is washed on a winch vat to which a nonionic washing agent has been added for about 20 minutes at moderate tetnperature. It is then heat fixed on a tentering frame at the temperature usually employed for the particular type of fiber, in the present case at about 188 C. to about 192 C. for poly-e-caprolaetam.
• the material is dyed a black shade on a jig with acid dyes.
• After rinsing and drying the fabric is napped. This is carried out in six passages through a 24 roller hosiery napping machine. Napping is carried out in the direction of the nap, starting with a low napping energy which is gradually increased during the subsequent passages.
• the napped fabric is passed three times at about 130 C. over a felt calender which has a diameter of about 2 m. Coating is carried out by first applying a clear undcrcoat having the following composition in a quantity of about parts of solids (setting ofdoctor wiper: doctor blade: 1 mm.).
• Coating of this material is carried out using a doctor applicator cover with a rubber sheet without the use of a supporting roller.
• the reverse coating has the following composition:
• polyester urethane prepolymer poly(ethylene glycol)
• polyester urethane prepolymer poly(ethylene glycol)
• hexanediol and neopentyl glycol pre-lengthened with tolylene diisocyanate in ethyl acetate
• acetic acid anhydride 50 parts of a solution of a basic accelerator which consists ofthe following individual components: 7 parts of phenyldiurethane, 3 parts of tetraoctacyltitanate, 45 parts of ethylene chloride, 45 parts of ethyl acetate 2 parts ofacetic acid, and 0.25 parts of acetic acid anhydride.
• the coating material is colored black and applied to a smooth silicone separating paper and united directly under slight pressure with the fabric which has been provided with an undercoat.
• the fabric is rolled up together with the separable material and unrolled after about 48 hours.
• a silicone finish is then applied by a doctor blade, After drying, the material is placed in a tumbler where it is rolled around for about 3 minutes at 70 C., the direction of rotation of the drum changing after every 10 revolutions.
• the diameter of the drum is about 150 cm.
• the finished fabric has a fine grain and attractive handle. It is taken out of the tumbler, spread out, stretched, while slightly damp and is at the same time rolled up.
• a process for producing coated textiles which comprises napping a tension stable 4-rail knitted fabric on one face and coating the napped face with a polyurethane coating composition and mechanically graining by tumbling the polyurethane coated napped fabric in an axial spin drier by rotating said dryer in alternate directions of rotation at a temperature of from about 20 C. to C.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Treatment Of Fiber Materials (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (1)

Publications (1)

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Family Applications (1)

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Cited By (9)

Families Citing this family (13)

Citations (4)

• 1968
  • 1968-04-25 DE DE19681760260 patent/DE1760260A1/de active Pending
• 1969
  • 1969-01-09 AT AT18269A patent/AT307360B/de not_active IP Right Cessation
  • 1969-01-24 GB GB4063/69A patent/GB1220561A/en not_active Expired
  • 1969-02-10 FR FR6903076A patent/FR2006872A1/fr not_active Withdrawn
  • 1969-02-17 BE BE728538D patent/BE728538A/xx unknown
  • 1969-02-27 BR BR206701/69A patent/BR6906701D0/pt unknown
  • 1969-03-24 US US809932A patent/US3650800A/en not_active Expired - Lifetime
  • 1969-04-22 SE SE5698/69A patent/SE342767B/xx unknown
  • 1969-04-23 NL NL6906271A patent/NL6906271A/xx unknown
  • 1969-04-25 ES ES366439A patent/ES366439A1/es not_active Expired

Patent Citations (4)

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