US3687712A - Wear resistant nonwoven fabric - Google Patents

Wear resistant nonwoven fabric Download PDF

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Publication number
US3687712A
US3687712A US3687712DA US3687712A US 3687712 A US3687712 A US 3687712A US 3687712D A US3687712D A US 3687712DA US 3687712 A US3687712 A US 3687712A
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US
United States
Prior art keywords
fabric
foam
nonwoven fabric
nonwoven
binder
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Expired - Lifetime
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English (en)
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Ludwig Hartmann
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Individual
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Individual
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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
    • 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
    • D04H3/12—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 filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • 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
    • Y10T428/31739—Nylon type
    • Y10T428/31743—Next to addition polymer from unsaturated monomer[s]
    • 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]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31935—Ester, halide or nitrile of addition polymer
    • 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]
    • Y10T442/647—Including a foamed layer or component
    • Y10T442/652—Nonwoven fabric is coated, impregnated, or autogenously bonded

Definitions

  • vnon-woven fabrics can be made of staple ber of a variety of kinds. It is further known that nonwoven fabrics can be made of substantially continuous filaments.v Y .Y
  • one aspect of this invention resides in a novel nonwoven fabic comprising substantially continuous laments in the shape of a fabric having bonding agentimpregnatedinto said fabric predominantly at the major surfaces thereof.
  • the wear-resistant nonwoven fabric of this invention lhave a substantially uniform batt structure consisting of thin, continuous polymer .laments which are bonded together with about 25 to 60% and, preferably, 40 to 50% binding agent, which batts are characterized in that over 60% of all laments thereof have a titer between 0.4 and 1.2 denier, and in that the binding agent is concentrated at the surfaces of the nonwoven fabric.
  • the continuous filaments of the batt are, in contrast to batts to carde'd staple fibers, substantially free of any kind of surface nishing agents, lubricants or other such substances on the surfaces thereof.
  • the continuous lament batts serving as starting material for the fabric of this invention are particularly suitable for the manufacture of outerwear types of nonwoven fabrics if they are made of especially ne filaments.
  • the fabric structure With uniform weight per unit 0f area and with the uniform batting achieved according to the above mentioned method of producing continuous lament battings, the fabric structure becomes increasingly dense .as the lament thickness is reduced, It is apparent that the lament fineness thus has a decisive influence on the breathability of the nonwoven fabric. If the lament diameters are too great, an excessively open structure is produced at a given weight per unit of area, giving an insufficient degree of coverage.
  • spun continuous lament batting produced according to the above-referred British patent are particularly well-suited for the manufacture of outerwear typesof products if their ber content consists of more than about 60% of filaments having a titer of less thanl about 1.2 denier and more than about 0.4 denier. It is not absolutely necessary for the entire amount of the bers to be within this range of titers. A small amount, e.g. about 5% of the filaments, may have a titer of less than about 0.4 denier. Furthermore, a larger percentage- -u ⁇ p to about 40--may have still coarser titers of -up to about 3 denier, if special characteristics are required.
  • the porosity of the fabric being made has an infiuence on its subsequent properties, and the porosity is adjustable according to the titer makeup of the fibers of the non-woven batting material.”
  • the porosity is adjustable according to the titer makeup of the fibers of the non-woven batting material.
  • the particles of binding agent are concentrated away from the core of theuonwoven batt and towards the two major surfaces thereof-buttllat enough binder is also in the middle of the fabric to prevent delamination. Itvshould be noted that, since the dispersed binder particles first deposit themselves along theiilament ization of the batting filamentary structure of the -nonwoven fabric subsequently obtained, which structure is permeated with capillaries.
  • concentrations of the bind ing agent in the impregnating foam-form fluid of upto a maximum of 20% are usable for the manufacture of the fabric according to the invention, with concentrations of ⁇ 6% to 10% being preferred.
  • concentrations of ⁇ 6% to 10% being preferred.
  • the wear-resistance of the nonwoven fabric diminishes rapidly. This can be explained by the fact that, after the complete impregnation of the loose batt, a migration of water towards both surfaces takes place in the drying, causing a certain amount of the binding agent particles to be thus carried towardl the surface before coagulation thereof is complete. This percent- 'addition of wetting agents stabilizes the foam-form disperf sion and promotes migration of binder particles to face.
  • the weight ratio of the binding .agent to the sur- "axes and especially at the filament intersections, the organthe filament weight is important. It has been found that the If a spun batting is impregnated with about 44% of apoly.-
  • the fabric has an air permeability of 940 l./sec./m.2 for a final .weight of 100 g./m.2 and an average titer of 0.8 denier; a similar fabric of 50 g./rn.2 has an air permeability of 1670 l./sec./m.2, i.e., the combined fiber and binding agent has porosities on the same order of magnitude as the plain fiber material, for comparable final weights.
  • both surfaces of the nonwoven fabric should contain a concentration of binding agent. l.
  • the filaments In order to obtain 4good adherence of the binding agent Y to the iilamentary structure, the filaments should be as free as possible from any kind of coatings of other subwill contain substantially equal amounts of binding agent, care being taken to see that, after the first surface has set, the other side is not too heavily loaded with the binder of the first impregnation process. Vln practice it has developedthat, in orderto achieve optimum adherence of the binding agent, the filamentsmust be substantially free of foreign. substances.
  • This processgcpan be performed 'particularlygwellif 'binding agents are used in the form of foarn because 'the .density and thickness of jtheffoarn permit the penetration of the fiber structure to be well-controlled'ln the'rst imf vpregnation, afoam of such a nature is applied that'it pene trates barely'beyond the center of the fiber material so that the second impregnation of the opposite side can be a'pplied to clean, so-called ..native, fibers.
  • a molten massof ⁇ polycaprolactarn at a temperature of 230 C. is spun into larnents 2.
  • the spinning apparatus hasv several'- nozzles with' 160 orifices 3 having avdiameter ofv400 microns.
  • the space between spinneret orifice amounted to 2 mm.
  • Hot air at a temperature of 240 C; was blasted at a velocity of ⁇ 200 m./sec. from the two air slits V4 running parallelfto the spnneretholes.
  • 1.5% had a diameter of less than 0.4 denier 84% had a diameter between 0.41 and 1.2 denier 14.5% had a diameter between 1.2 and 1.8 denier.
  • the roller pressure is to be adjusted so that the binding agent does not penetrate to the bottom side.
  • the batting thus impregnated is carried into a drying chamber 9 where air at 120 C. is blown onto the surface of the batting on which the foam had been applied.
  • a migration of the binding agent to the hotter surface takes place.
  • a concentration of the binding agent takes place at the surface to which the foam has just been applied. If during the impregnation an amount of binding agent should have penetrated through to the bottom surface, it would largely migrate back again during the drying. In this manner the bottom side remains loose-fibered.
  • the web 10 of material After leaving the dryer the web 10 of material is inverted and the impregnation process is repeated under the same conditions.
  • the double impregnated web 11 is dried again at 120 C. and heated for another three minutes at 150 C. in a dryer 12 to thoroughly condense the binding agent.
  • the resulting nonwoven fabric manufactured in this manner weighed 50 g./m.2 and had good resistance to washing and dry-cleaning. Its air permeability amounted to 1650 l./sec./m.2 at 10 mm. water column AP.
  • a wear resistant nonwoven textile fabric comprising a web of varying denier substantially continuous filaments having at least about 60% of said filaments with deniers of 0.4 to 2.0 bonded together throughout at the intersections thereof with an acrylic bonding agent comprising about 25 to 60 weight percent of said fabric, which bond- 6 ing agent is concentrated at and substantially adjacent to the two major surfaces thereof, and is also present in the middle of the fabric to an extent sufiicient to prevent delamination of said fabric.
  • said bonding agent is a cross-linked polymer of acrylonitrile, n-butylacrylate and N-methylolacrylamide.
  • Process of producing a nonwoven fabric as claimed in claim 1, comprising; preparing a non-woven web of thermoplastic substantially continuous filaments; preparing a Huid-foam impregnant composition comprising an aqueous dispersion of an acrylic resin having a solids content of up to about 20 weight percent; coating said uid foam onto a first major surface of said non-woven web and impregnating such foam into said web; heating said coated and impregnated web to a temperature and for a time sufficient to substantially remove the liquid portion of the impregnant, to cause said resin to migrate toward said heat and to deposit said resin substantially at and adjacent to said first major surface; coating the second major surface of said nonwoven web with a second aliquot of said fiuid foam and impregnating such foam into said web; and heating said second coated and impregnated web to a temperature and for a time suicient to substantially remove the liquid portion of the impregnant, to cause said resin to migrate toward said heat and to deposit said resin substantially at and adjacent
US3687712D 1968-02-10 1968-04-16 Wear resistant nonwoven fabric Expired - Lifetime US3687712A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP832268A JPS553469B1 (de) 1968-02-10 1968-02-10

Publications (1)

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US3687712A true US3687712A (en) 1972-08-29

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Family Applications (1)

Application Number Title Priority Date Filing Date
US3687712D Expired - Lifetime US3687712A (en) 1968-02-10 1968-04-16 Wear resistant nonwoven fabric

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US (1) US3687712A (de)
JP (1) JPS553469B1 (de)
GB (1) GB1262347A (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3865661A (en) * 1972-03-10 1975-02-11 Tokuyama Sekisui Ind Corp Process for manufacturing a porous thermoplastic resin article reinforced by a glass matt
US3955577A (en) * 1974-03-18 1976-05-11 The Procter & Gamble Company Resin treated absorbent pad or web for body fluids
US3993805A (en) * 1972-07-31 1976-11-23 Concorde Fibers Inc. Method of applying liquid finish composition to filaments
US4159355A (en) * 1977-11-14 1979-06-26 Scott Paper Company Foam bonding
US4263358A (en) * 1975-03-01 1981-04-21 Bodina, Ltd. Multizonal binder impregnation
US20040217507A1 (en) * 2001-09-06 2004-11-04 Alain Yang Continuous process for duct liner production with air laid process and on-line coating

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3217735C2 (de) * 1982-05-12 1985-01-17 Akzo Gmbh, 5600 Wuppertal Verfahren zur Herstellung eines beschichteten textilen Flächengebildes
JPS59151488U (ja) * 1983-03-30 1984-10-11 株式会社日立製作所 電子機器の組立構造

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3865661A (en) * 1972-03-10 1975-02-11 Tokuyama Sekisui Ind Corp Process for manufacturing a porous thermoplastic resin article reinforced by a glass matt
US3993805A (en) * 1972-07-31 1976-11-23 Concorde Fibers Inc. Method of applying liquid finish composition to filaments
US3955577A (en) * 1974-03-18 1976-05-11 The Procter & Gamble Company Resin treated absorbent pad or web for body fluids
US4263358A (en) * 1975-03-01 1981-04-21 Bodina, Ltd. Multizonal binder impregnation
US4159355A (en) * 1977-11-14 1979-06-26 Scott Paper Company Foam bonding
US20040217507A1 (en) * 2001-09-06 2004-11-04 Alain Yang Continuous process for duct liner production with air laid process and on-line coating
US7815967B2 (en) * 2001-09-06 2010-10-19 Alain Yang Continuous process for duct liner production with air laid process and on-line coating

Also Published As

Publication number Publication date
GB1262347A (en) 1972-02-02
JPS553469B1 (de) 1980-01-25

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