US3809589A - Method for making pile fabric - Google Patents

Method for making pile fabric Download PDF

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Publication number
US3809589A
US3809589A US20615071A US3809589A US 3809589 A US3809589 A US 3809589A US 20615071 A US20615071 A US 20615071A US 3809589 A US3809589 A US 3809589A
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US
United States
Prior art keywords
fibres
adhesive
fabric
pile
layer
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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English (en)
Inventor
V Kerstetter
L Mizell
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IWS Nominee Co Ltd
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IWS Nominee Co Ltd
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Publication date
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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12Q—MEASURING OR TESTING PROCESSES INVOLVING ENZYMES, NUCLEIC ACIDS OR MICROORGANISMS; COMPOSITIONS OR TEST PAPERS THEREFOR; PROCESSES OF PREPARING SUCH COMPOSITIONS; CONDITION-RESPONSIVE CONTROL IN MICROBIOLOGICAL OR ENZYMOLOGICAL PROCESSES
    • C12Q1/00—Measuring or testing processes involving enzymes, nucleic acids or microorganisms; Compositions therefor; Processes of preparing such compositions
    • C12Q1/68—Measuring or testing processes involving enzymes, nucleic acids or microorganisms; Compositions therefor; Processes of preparing such compositions involving nucleic acids
    • C12Q1/6844—Nucleic acid amplification reactions
    • C12Q1/6851—Quantitative amplification
    • 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
    • D04H11/00—Non-woven pile fabrics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H4/00—Swimming or splash baths or pools
    • E04H4/12—Devices or arrangements for circulating water, i.e. devices for removal of polluted water, cleaning baths or for water treatment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H4/00—Swimming or splash baths or pools
    • E04H4/14—Parts, details or accessories not otherwise provided for
    • E04H4/16—Parts, details or accessories not otherwise provided for specially adapted for cleaning
    • E04H4/1618—Hand-held powered cleaners
    • E04H4/1636—Suction cleaners
    • 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
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23986—With coating, impregnation, or bond

Definitions

  • Flexible pile fabrics are made by bending the end portions of the fibres in a surface of an array of aligned fibres, setting the fibres in the bent state, and securing the bent fibre ends in a layer of adhesive.
  • Suitably aligned fibres arrays may be made by severing the projecting fires of a furred animal skin, such as raw or pickled wooled skins, or of an artificial fabric having projecting fibres of natural or synthetic origin.
  • a fabric backing material may be adhered to the face of the pile fabric carrying the adhesive layer before or after the setting of the adhesive.
  • This invention relates to the production of pile fabrics comprising natural or synthetic fibres which are secured in a layer of adhesive.
  • the invention is particularly concerned with the production of flexible pile fabrics having good handle and drape properties, e.g. as blanket material, apparel fabrics and filter fabrics.
  • a method of making a pile which comprises:
  • the bending of the fibre ends in the surface of the array is an important step in the process, and by setting them in this bent state it enables a small amount of adhesive to achieve a larger bonding effect than if the fibres were in an unbent state.
  • the bent fibres overlap and cross one another, leaving a portion of the length of the fibres exposed in the surface, and ready to receive adhesive; the major proportion of the length of each fibre is below the surface plane and is protected from adhesive by neighboring or overlapping fibres.
  • the adhesive layer is, in effect, reinforced by the ends of the fibres which have been bent and form part of that layer. In this way maximum use is made of the minimum amount of adhesive.
  • Suitably aligned fibre arrays may be made by severing the projecting fibres from an existing pile fabric, e.g. a furred animal skin or an artificial piled fabric having projecting fibres of natural or synthetic fibres.
  • an existing pile fabric e.g. a furred animal skin or an artificial piled fabric having projecting fibres of natural or synthetic fibres.
  • Particularly suitable for use in the method of the invention are raw or pickled wooled sheepskins; sliver-knit pile fabrics may also be used.
  • Pile fabrics useful in the method of the invention include sliver-knit and other piled fabrics having uniform or tufted piles or naps of natural or synthetic fibres including wool and wool-like fibres, cellulose and cellulosebased fibres and artificial or synthetic fibres of all types.
  • the adhesive may be applied to the outer ends of the fibres before or after the fibres are severed from the fabric or to the cut ends of the fibres after severance. It is preferred, however, to apply the adhesive to the cut ends of the fibres.
  • the end portions of the fibres in the surface of the array may be bent by applying pressure to the fibres in a direction substantially parallel to the normal fibre direction, i.e. at right angles to the surface formed by the fibre tips and this may be conveniently achieved by means of a flat bed press or a pair of calendering rolls.
  • pressure i.e. at right angles to the surface formed by the fibre tips
  • this may be conveniently achieved by means of a flat bed press or a pair of calendering rolls.
  • heat to the fibres in the presence of water in order to set the fibres in the bent state.
  • steam may be applied during the pressure step or, alternatively, the fibres may be wetted before the pressure step.
  • artificial fibres setting of the fibres may be achieved by the usual methods, e.g. by the application of heat or pressure or both.
  • bending and setting of the fibres in the bent state may be carried out in one operation and this is usually the most convenient way in which to operate the process according to the invention.
  • the two operations may be carried out sequentially, that is to say bending followed by setting, provided that the fibres retain their bent position long enough for them to be set in that position.
  • the fibres may be secured in a discontinuous layer of adhesive and this method of bonding leads to exceptionally flexible pile fabrics.
  • Such discontinuous layers of adhesive also make the pile fabric porous, and thus particularly suitable for use as blanket material and for applications in filtering and humidfying applications.
  • the adhesive may be applied to the bent fibre ends by any of the known methods, for example, by knife coating techniques, the preferred discontinuous layer may be obtained by depositing the adhesive 3 in the form of discrete droplets onto the bent ends of the fibres.
  • a wide range of adhesives may be utilized for forming the adhesive layer of the pile fabrics of the invention, including polyacrylics, polyurethanes, epoxies, Neoprenes, butadiene-styrene copolymers, polyesters, polyamides, phenolics and animal and vegetable glues.
  • polyacrylic latex adhesives such as Rhoplex E-30 and Rhoplex E-32 of Rohm & Haas Co., applied, for example, at a rate to deposit about 4 ounces of solids per square yard of fabric when dried.
  • Adhesives which set under conditions in which the fibres do not melt or otherwise undergo degradation are, of course, desirable.
  • the adhesive may be allowed to dry or cure itself at ambient temperatures, but it is usually preferable to include a heating step, e.g. to a temperature in the range 30 to 150 C., to speed up the process.
  • a reinforcing backing fabric may be applied to the layer of adhesive at the base of the pile fabric and may be applied before or after the adhesive is dry.
  • Backing fabrics may be woven, knitted, felted or otherwise consolidated porous web structures of natural or synthetic fibrous materials.
  • thermoplastic or hot-melt adhesive As an alternative method of securing the bent fibre ends in a layer of adhesive there may be used as the adhesive a heat-softened thermoplastic or hot-melt adhesive.
  • the bent ends of the fibres may be secured by applying the softened thermoplastic to them, for example by means of a curtain coater.
  • the thermoplastic material selected should have a melting point below the melting point, if any, of the fibres with which it is to be used.
  • the film-backed fabric so produced may be.
  • thermoplastic material laminated to a further fabric-backing material, such as cotton flannel or cheesecloth, before, at or subsequent to the embedding of the array of fibres in the thermoplastic material.
  • the fibres When using arrays of severed fibres, the fibres may be urged into closer juxtaposition in the array before applying the adhesive to the bent end portion of the fibres.
  • the arrays of severed fibres from a plurality of skins may be urged into close association at the edges of the arrays to form consolidated array before applying the adhesive particles or a plurality of skins may be adhered together in edge to edge relation to form an extended structure, for example, by adhering the flesh side of the skins or the free tip ends of the fibres to a temporary tacky support of paper, fabric or the like and thereafter severing the fibres.
  • a temporary support may be applied to the outer ends of the projecting fibres of pile fabrics before the fibres are severed from the fabric.
  • the length of the fibres in the pile of the fabrics of the invention will be in the range from about A to 1% inch although piles of longer or shorter lengths can be made by the method of the invention.
  • the pile starting material can have fibre lengths up to 4 inches or more.
  • FIG. 1 is a longitudinal section through apparatus for cutting an array of fibres from a piled article, forming a discontinuous adhesive layer on one face of the array of fibres and applying a fabric backing to the adhesive layer;
  • FIG. 2 is an enlarged fragmentary perspective showing of a portion of an array of fibres to which a layer of discontinuously contiguous adhesive droplets have been applied;
  • FIG. 3 is an enlarged fragmentary longitudinal section 'showing diagrammatically the structure of the porous piled fabric produced by the method illustrated in FIG. 1;
  • FIG. 4 is a further enlargement of the piled fabric of FIG. 3;
  • FIG. 5 is a section on line 55 of FIG. 4;
  • FIG. 6 is a longitudinal section through apparatus generally similar to FIG. 1 but including means for applying a temporary supporting web to one face of the array of fibres;
  • FIG. 7 is a longitudinal section through apparatus generally similar to that of FIG. 1.
  • FIG. 1, 1 are Wool skins which are passed by conveyor belt 2, which may be of glass ,bre coated with Teflon or silicone, and suction roll 3 into cutter block 4- of a band knife machine.
  • the arrays 5 of wool fibres cut from the skins are bent over at their cut ends by heated roll 6, which may be heated up to 400 F. and maintained at a pressure against roll 6 of from about 50 to about 500 p.s.i.
  • heated roll 6 After passing rolls 6, 6' a spray of adhesive particles is projected on the bent upper ends of the fibres by spray nozzles 7 in spray hood 8, forming a layer 9 (FIG. 2) of discontinuously contiguous particles.
  • the adhesive is dried and indurated by passing the ensemble under bank 13 of infra red lamps.
  • FIGS. 3, 4 and 5 show more clearly the porous and flexible structure of the pile fabric produced by the method illustrated in FIG. 1, including the array 5, the discontinuous layer 9 of adhesive and the fibrous backing layer 10.
  • a temporary support layer of gummed paper 14 from supply roll 15 is moistened by roll 16 and applied by rolls 17, 17' to the outer ends of the pile of sliver-knit pile fabric 18, which is then fed by roll 19 into cutter blade 4 of a band knife machine.
  • Fibre array 5 is then flattened by roll 6, discontinuously coated with a spray of adhesive by nozzles 7 and after applying a fabric backing 10, the adhesive is cured by heater 13.
  • the temporary support 14 is then removed at 20 and the resulting pile constituted by the fibre array 5 is brushed up by steam brush 21.
  • the fibre array 5, cut from pile fabric 14- by knife 4 is carried through the fibre: bending rolls 6, 6', adhesive spray 7, backing applier rolls 12, 12., and curing lamps 13 on conveyor belt 2.
  • the method of the invention is a faster process than those used hitherto for the production of pile fabrics.
  • the pile fibre ends are pressed into a layer of adhesive and held there for 2 to 3 minutes, whereas the only pressure step in the method of the invention is the pressing and setting of the fibre ends, which step takes 15 seconds or less in a flat bed press or can be made continuous when a heated pressure nip or similar pair of surfaces is used. It is to be noted that the prior art processes do not lead to the production of flexible pile fabrics having good handle and good drape.
  • a method of making a pile fabric consisting of the steps of providing an array of aligned fibres, urging the end portions of the fibres in a surface layer of the array to bend so that said portions are bent at an angle to the normal directions of the fibres in the array, setting said bent portions of the fibres in the bent state, and thereafter solely securing the set bent portions of the fibres into a continuous flexible layer by depositing adhesive on the bent and set portions of the fibres in the form of discontinuous and discrete droplets of the adhesive.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Zoology (AREA)
  • Proteomics, Peptides & Aminoacids (AREA)
  • Health & Medical Sciences (AREA)
  • Architecture (AREA)
  • Bioinformatics & Cheminformatics (AREA)
  • Genetics & Genomics (AREA)
  • Microbiology (AREA)
  • Molecular Biology (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Biotechnology (AREA)
  • Biochemistry (AREA)
  • Biophysics (AREA)
  • General Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Immunology (AREA)
  • Textile Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Woven Fabrics (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Nonwoven Fabrics (AREA)
US20615071 1969-01-09 1971-12-08 Method for making pile fabric Expired - Lifetime US3809589A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB147969A GB1291862A (en) 1969-01-09 1969-01-09 Pile fabric
US96170A 1970-01-06 1970-01-06

Publications (1)

Publication Number Publication Date
US3809589A true US3809589A (en) 1974-05-07

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ID=26668361

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Application Number Title Priority Date Filing Date
US20615071 Expired - Lifetime US3809589A (en) 1969-01-09 1971-12-08 Method for making pile fabric

Country Status (5)

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US (1) US3809589A (de)
JP (1) JPS5025071B1 (de)
CA (1) CA920042A (de)
DE (1) DE2000438A1 (de)
GB (1) GB1291862A (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050233106A1 (en) * 2002-01-10 2005-10-20 Hayashi Engineering Inc. Floor laying material, piece mat, and arranging structure thereof
US20130255048A1 (en) * 2012-03-30 2013-10-03 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US10801139B2 (en) 2017-01-27 2020-10-13 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting
US11713524B2 (en) 2017-01-27 2023-08-01 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050233106A1 (en) * 2002-01-10 2005-10-20 Hayashi Engineering Inc. Floor laying material, piece mat, and arranging structure thereof
US20130255048A1 (en) * 2012-03-30 2013-10-03 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US9212440B2 (en) * 2012-03-30 2015-12-15 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US10287720B2 (en) 2012-03-30 2019-05-14 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US10801139B2 (en) 2017-01-27 2020-10-13 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting
US11713524B2 (en) 2017-01-27 2023-08-01 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting

Also Published As

Publication number Publication date
DE2000438A1 (de) 1970-09-17
JPS5025071B1 (de) 1975-08-20
CA920042A (en) 1973-01-30
GB1291862A (en) 1972-10-04

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