US3853659A - Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas - Google Patents

Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas Download PDF

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Publication number
US3853659A
US3853659A US00319132A US31913272A US3853659A US 3853659 A US3853659 A US 3853659A US 00319132 A US00319132 A US 00319132A US 31913272 A US31913272 A US 31913272A US 3853659 A US3853659 A US 3853659A
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United States
Prior art keywords
fibers
hydrogen halide
bonding
halide gas
gas
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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
Application number
US00319132A
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English (en)
Inventor
J Rhodes
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Fiberweb North America Inc
Original Assignee
Monsanto Co
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Filing date
Publication date
Application filed by Monsanto Co filed Critical Monsanto Co
Priority to US00319132A priority Critical patent/US3853659A/en
Priority to NL7317703A priority patent/NL7317703A/xx
Priority to CA189,060A priority patent/CA1002398A/en
Priority to AU64043/73A priority patent/AU461081B2/en
Priority to LU69085A priority patent/LU69085A1/xx
Priority to DE2365004A priority patent/DE2365004A1/de
Priority to IT32407/73A priority patent/IT1017531B/it
Priority to BE139387A priority patent/BE809246A/xx
Priority to FR7347033A priority patent/FR2212456B1/fr
Priority to JP744297A priority patent/JPS5113790B2/ja
Priority to GB6008473A priority patent/GB1417269A/en
Application granted granted Critical
Publication of US3853659A publication Critical patent/US3853659A/en
Assigned to JAMES RIVER-NORWALK, INC., A CORP OF DELAWARE reassignment JAMES RIVER-NORWALK, INC., A CORP OF DELAWARE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: MONSANTO COMPANY, A CORP OF DE.
Assigned to FIBERWEB NORTH AMERICA, INC., 545 NORTH PLEASANTBURG DRIVE, GREENVILLE, SC 29607, A CORP. OF DE reassignment FIBERWEB NORTH AMERICA, INC., 545 NORTH PLEASANTBURG DRIVE, GREENVILLE, SC 29607, A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: JAMES RIVER PAPER COMPANY, INC., A CORP. OF VA
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • D04H3/14—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 bonds between thermoplastic yarns or filaments produced by welding
    • 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

Definitions

  • bers which comprise a mat to at least 2% based on the weight of the fiber, subjecting the mat to a gaseous atmosphere containing less than 2% by volume of a hydrogen halide gas and greater than about 0.5% by volume of water vapor to increase the moisture regain of the nylon toat least 3% based on weight with said fibers absorbing at least 2% of the hydrogen halide gas based on weight and completing the bonding of the fibers by pressing the fibers together while the fibers contain the mentioned water and hydrogen halide gas and by removing the hydrogen halide gas from the fi- 3,542,615 11/1970 Dobo et a1. 156/181 bers I 3,555,806 1/1971 Knudsen et al.
  • Mallonee et al subjected nylon fibers to a hydrogen chloride gas, allowed the fibers to absorb quantities of the hydrogen chloride gas, placed the fibers in intimate contact with each other, and removed or desorbed the hydrogen chloride gas from the fibers by means of either heat or a wash water bath. The result was a bond formed at the touching cross-over of the various fibers.
  • a self-bonded, non-woven fabric could be produced from a polymer melt in a single continuous operation.
  • Continuous nylon filaments were spun from a polymer melt, pneumatically attenuated and deposited onto a moving surface or conveyor belt in the form of an unbonded mat.
  • the continuous filaments comprising the mat were arranged without apparent order.
  • the mat was advanced through a chamber filled with an activating gas and was allowed to remain therein a time sufficient topermit surface absorption of the gas into the filaments.
  • The'fibrous mat containing the absorbed gas was calendered to improve contact between filaments. Thereafter the gas was desorbed or neutralized by exposing the mat to a wash water bath or to a heated environment whereby interfilament bonding was completed.
  • the present invention contemplates the formation of a non-woven web which is comprised of nylon filaments, the filaments being autoge nously bonded together at a substantial number of touching filament cross-over points.
  • the invention is the special handling of the nylon filaments prior to their entrance into the gas box, during the residing time in the gas box and subsequent to the gas box which includes the pressing of the fibers together while the fibers are in said conditioned state.
  • the nylon fibers which comprise the unbonded mat are prepared for bonding by increasing the moisture regain thereofto at least 2% based on the weight of the fiber.
  • the mat is then subjected to a gaseous atmosphere containing less than 2% by volume of a hydrogen halide gas and greater than about 0.5% by volume of water vapor to increase the moisture regain of the nylon to at least 3% based on the weight of the fibers and to allow the nylon fibers to absorb at least 2% hydrogen halide gas based on the weight of the fibers.
  • Bonding of the fibrous mat to form the non-woven web is completed by pressing the fibers together while the fibers contain the mentioned water and hydrogen halide gas and by removing the hydrogen halide gas from the fibers subsequent to pressing preferably by means of a water wash bath.
  • Moisture regain is the amount of water on a weight basis present in the nylon fiber as compared to the weight of the nylon fiber in the dry state.
  • the FIGURE is a block diagram showing the various process steps throughwhich the nylon is passed.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT standard abrasive element is an S32 wheel.
  • the disc after having received fabric is rotated at a speed of 72 rpm.
  • Fabric failure is determinedwhen six filaments have been raised at least one-eighth of an inch above the surface of the fabric.
  • the fabric must pass at least five revolutions beneath the abrading element without having six filaments raised to at least one-eighth of an inch above the surface of the fabric.
  • this test will be referred to as the Taber abrasion test.
  • the mat of unbonded nylon fibers may be formed by means of a variety of methods.
  • the fibers may be either staple or continuous filament.
  • the unbonded mat of fibers shall be formed by the method taught in U.S. Pat. No. 3,542,615 to Dobo et al, and therefore, the filaments will be continuous.
  • the continuous nylon filaments are spun from a nylon polymer melt, after which the filaments are attenuated and forwarded to a moving foraminous belt for collection.
  • a preconditioning chamber which is maintained. at a controlled humidity level in order to provide a moisture regain of at least 2%.
  • the dwell time at each process step is less than 60 seconds. It has been found that nylon filaments do not readily absorb a hydrogen halide gas such as, for example, hydrogen chloride gas to the extent necessary to provide adequate bonding which is approximately 2% and above. Also, the nylon filaments must regain at least 3% moisture based on the weight of the fibers. Although the bonding and moisture chamber contain quantities of water vapor, the dwell time therein does not permit the moisture regain of at least 3% nor the subsequent absorption of the gas to at least 2% based on the weight of the fiber without the filaments having regained at least 2% moisture prior to entrance into the bonding gas and moisture chamber.
  • a hydrogen halide gas such as, for example, hydrogen chloride gas
  • Conditions in the bonding gas and moisture chamber are also critical. when the process is run at the contemplated commercial speeds, the swell time in the bonding gas and moisture chamber is no greater than 40 seconds. Therefore, moisture regain and absorption of the hydrogen halide gas into the nylon fibers must occur rapidly. Thus, the content of the gaseous atmosphere within the mentioned chamber becomes critical. The temperature must range between 50 and 120F. Below 50F. sufficient moisture is not available within the chamber to allow the required moisture regain to take place and, at above lOF., both the moisture and the absorbed hydrogen halide gas have a tendency to be volatilized from the filaments. The balance between the volume of the hydrogen halide gas and the volume of water vapor present in the gaseous atmosphere is also critical.
  • the nylon fibers Upon exiting the bonding gas and moisture chamber, it is critical that the nylon fibers maintain the abovementioned percentages of hydrogen halide gas and moisture for, if the moisture is allowed to evaporate from the fibers to the degree where the fibers contain less than 3% moisture regain based on the weight of the fibers, the fibers lose their surface tackiness and will not readily adhere to each other when pressed together. Therefore, conditions are to be maintained in the area between the bonding gas and moisture chamber and the press rolls such that moisture will not be lost from the fibers. Pressing is generally accomplished by means of calender-type press rolls which may or may not be embossed.
  • the filaments are in intimate contact and bonding is completed by removing the hydrogen halide gas therefrom. While the hydrogen halide gas may be removed or desorbed from the bonded web by heat means, it is preferred to-pass the web through a water wash bath. Once the hydrogen halide gas is removed from the filaments, bonding is complete. The bonded web is then dried and packaged by any suitable take-up means.
  • a mat of continuous nylon 66 filaments was prepared by the standard spunbonded process which includes spinning nylon filaments, attenuating the filaments and forwarding thefilaments to a moving foraminous belt for collection.
  • the unbonded mat weighed approximately 1.0 oz. per square yard.
  • the mat in its unbonded state, was subjected to the preconditioning chamber.
  • the mat had a moisture content entering the preconditioning chamber of 1.5% based on the weight of the mat.
  • the temperature of the preconditioning chamber was F. and the relative humidity was 60%.
  • the mat was exposed to the atmospheric conditions in the preconditioning chamber for approximately 40 seconds. Upon leaving the preconditioning chamber the moisture regain of the mat was 2.2%.
  • the mat was then subjected to the bonding gas and moisture chamber.
  • the chamber contained 0.9% by volume of the hydrogen chloride gas and 1.3% by volume of water vapor.
  • the temperature within the chamber was 92F. which was approximately 16 above the saturation or dew point for that particular atmospheric condition.
  • the mat was exposed to the conditions within the bonding gas and moisture chamber for approximately 12 seconds. Upon leaving the bonding gas and moisture chamber, the mat picked up 4.0% by weight of the hydrogen chloride gas and had a total moisture regain of 4.8% by weight.
  • the fibrous mat was then pressed by being passed through cooperating calender rolls, the rolls exerting a net pressure of pounds per linear inch.
  • Interfilament bonding was completed by passing the mat through a water wash bath which removes or desorbs substantially all of the hydrogen chloride gas from the filaments. The resulting bonded web was then dried.
  • EXAMPLE 11 The basic process steps of Example I were repeated with the changes being made in the preconditioning chamber and the bonding gas and moisture chamber.
  • Preconditioning Chamber Moisture of Mat Entering 1.8% by weight Exposure Time 9 seconds Temperature 59F.
  • a process for transforming an unbonded fibrous mat of nylon fibers into a high-strength bonded nonwoven web comprising the steps of:
  • nylon fibers are continuous nylon filaments.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
US00319132A 1972-12-29 1972-12-29 Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas Expired - Lifetime US3853659A (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
US00319132A US3853659A (en) 1972-12-29 1972-12-29 Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas
NL7317703A NL7317703A (lm) 1972-12-29 1973-12-27
JP744297A JPS5113790B2 (lm) 1972-12-29 1973-12-28
LU69085A LU69085A1 (lm) 1972-12-29 1973-12-28
DE2365004A DE2365004A1 (de) 1972-12-29 1973-12-28 Verfahren zur verbesserung der bindung von nylon-endlosfaeden unter verwendung von chlorwasserstoffgas
IT32407/73A IT1017531B (it) 1972-12-29 1973-12-28 Procedimento per migliorare i le gami di filamenti di super poliammi di lineari mediante l uso di acido cloridrico gassoso
CA189,060A CA1002398A (en) 1972-12-29 1973-12-28 Method for improving the bonding of nylon filaments by the use of an hydrogen chloride gas
FR7347033A FR2212456B1 (lm) 1972-12-29 1973-12-28
AU64043/73A AU461081B2 (en) 1972-12-29 1973-12-28 Method for improving the bonding of nylon filaments bythe use ofan hydrogen halide gas
GB6008473A GB1417269A (en) 1972-12-29 1973-12-28 Bonding process
BE139387A BE809246A (fr) 1972-12-29 1973-12-28 Methode pour ameliorer la liaison entre filaments de nylon en utilisant de l'acide chlorhydrique gazeux

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US00319132A US3853659A (en) 1972-12-29 1972-12-29 Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas

Publications (1)

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US3853659A true US3853659A (en) 1974-12-10

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US00319132A Expired - Lifetime US3853659A (en) 1972-12-29 1972-12-29 Method for improving the bonding of nylon filaments by the use of a hydrogen halide gas

Country Status (11)

Country Link
US (1) US3853659A (lm)
JP (1) JPS5113790B2 (lm)
AU (1) AU461081B2 (lm)
BE (1) BE809246A (lm)
CA (1) CA1002398A (lm)
DE (1) DE2365004A1 (lm)
FR (1) FR2212456B1 (lm)
GB (1) GB1417269A (lm)
IT (1) IT1017531B (lm)
LU (1) LU69085A1 (lm)
NL (1) NL7317703A (lm)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4075383A (en) * 1976-04-15 1978-02-21 Monsanto Company Method of pattern bonding a nonwoven web
US4168195A (en) * 1976-04-15 1979-09-18 Monsanto Company Method of autogenously bonding a nonwoven polyamide web
US4396452A (en) * 1978-12-21 1983-08-02 Monsanto Company Process for point-bonding organic fibers
US5431986A (en) * 1994-07-18 1995-07-11 Cerex Advanced Fabrics, L. P. Spunbonded nonwoven nylon fabrics
US20010055682A1 (en) * 1998-09-14 2001-12-27 Ortega Albert E. Novel nonwoven fabrics with advantageous properties
US20020195196A1 (en) * 2001-06-23 2002-12-26 Steag Microparts Gmbh Process for the flush connection of bodies
US20030049988A1 (en) * 1998-09-14 2003-03-13 Ortega Albert E. Nonwoven fabrics with two or more filament cross sections
US20030096549A1 (en) * 2001-10-18 2003-05-22 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
US20040216828A1 (en) * 2001-08-17 2004-11-04 Ortega Albert E. Nonwoven fabrics with two or more filament cross sections
EP2368698A1 (en) 2010-03-24 2011-09-28 Cerex Advanced Fabrics, Inc. Fiber-reinforced plastic parts made with untreated embossed surfacing veils with no whitening agents

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL7703952A (nl) * 1976-04-15 1977-10-18 Monsanto Co Werkwijze voor het binden of hechten van een niet geweven baan of vel, alsmede het produkt van deze werkwijze.
US4065399A (en) * 1976-09-17 1977-12-27 Monsanto Company Process for controlling a bonding gas system
AU531418B2 (en) * 1978-09-11 1983-08-25 Philip Morris Products Inc. Cigarette filters
TR201101163A2 (tr) 2011-02-08 2011-10-21 Bortek Bor Teknoloji̇leri̇ Ve Mekatroni̇k Sanayi̇ Ve Ti̇caret Li̇mi̇ted Şi̇rketi̇ Fosfat kaplamanın özelliklerini iyileştirme yöntemi.

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3516900A (en) * 1966-02-16 1970-06-23 Monsanto Co Gas activated bonding of polyamides
US3542615A (en) * 1967-06-16 1970-11-24 Monsanto Co Process for producing a nylon non-woven fabric
US3555806A (en) * 1968-12-18 1971-01-19 Monsanto Co Porous nylon fiber rods
US3676244A (en) * 1970-06-29 1972-07-11 Monsanto Co Process for forming high strength spunbonded fabric by autogenous bonding of filaments

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3516900A (en) * 1966-02-16 1970-06-23 Monsanto Co Gas activated bonding of polyamides
US3542615A (en) * 1967-06-16 1970-11-24 Monsanto Co Process for producing a nylon non-woven fabric
US3555806A (en) * 1968-12-18 1971-01-19 Monsanto Co Porous nylon fiber rods
US3676244A (en) * 1970-06-29 1972-07-11 Monsanto Co Process for forming high strength spunbonded fabric by autogenous bonding of filaments

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4075383A (en) * 1976-04-15 1978-02-21 Monsanto Company Method of pattern bonding a nonwoven web
US4168195A (en) * 1976-04-15 1979-09-18 Monsanto Company Method of autogenously bonding a nonwoven polyamide web
US4396452A (en) * 1978-12-21 1983-08-02 Monsanto Company Process for point-bonding organic fibers
US5431986A (en) * 1994-07-18 1995-07-11 Cerex Advanced Fabrics, L. P. Spunbonded nonwoven nylon fabrics
US20030104747A1 (en) * 1998-09-14 2003-06-05 Ortega Albert E. Novel nonwoven fabrics with advantageous properties
US7060149B2 (en) 1998-09-14 2006-06-13 The Procter & Gamble Company Nonwoven fabrics with advantageous properties
US20030049988A1 (en) * 1998-09-14 2003-03-13 Ortega Albert E. Nonwoven fabrics with two or more filament cross sections
US8088696B2 (en) 1998-09-14 2012-01-03 The Procter & Gamble Company Nonwoven fabrics with advantageous properties
US20010055682A1 (en) * 1998-09-14 2001-12-27 Ortega Albert E. Novel nonwoven fabrics with advantageous properties
US20060252332A9 (en) * 1998-09-14 2006-11-09 Ortega Albert E Nonwoven fabrics with two or more filament cross sections
US20020195196A1 (en) * 2001-06-23 2002-12-26 Steag Microparts Gmbh Process for the flush connection of bodies
US7238246B2 (en) * 2001-06-23 2007-07-03 Boehringer Ingelheim Microparts Gmbh Process for the flush connection of bodies
US20040216828A1 (en) * 2001-08-17 2004-11-04 Ortega Albert E. Nonwoven fabrics with two or more filament cross sections
US20040221436A1 (en) * 2001-10-18 2004-11-11 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
US7174612B2 (en) 2001-10-18 2007-02-13 Cerex Advanced Fabrics, Inc. Nonwoven fabrics containing yarns with varying filament characteristics
US7175902B2 (en) 2001-10-18 2007-02-13 Cerex Advanced Fabrics, Inc. Nonwoven fabrics containing yarns with varying filament characteristics
US20030096549A1 (en) * 2001-10-18 2003-05-22 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
EP2368698A1 (en) 2010-03-24 2011-09-28 Cerex Advanced Fabrics, Inc. Fiber-reinforced plastic parts made with untreated embossed surfacing veils with no whitening agents
US20110236638A1 (en) * 2010-03-24 2011-09-29 Ortega Albert E Fiber-Reinforced Plastic Parts Made With Untreated Embossed Surfacing Veils With No Whitening Agents

Also Published As

Publication number Publication date
AU461081B2 (en) 1975-05-15
IT1017531B (it) 1977-08-10
LU69085A1 (lm) 1974-08-19
GB1417269A (en) 1975-12-10
NL7317703A (lm) 1974-07-02
FR2212456B1 (lm) 1978-04-07
JPS5052369A (lm) 1975-05-09
FR2212456A1 (lm) 1974-07-26
AU6404373A (en) 1975-05-15
CA1002398A (en) 1976-12-28
DE2365004A1 (de) 1974-07-11
BE809246A (fr) 1974-06-28
JPS5113790B2 (lm) 1976-05-04

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Legal Events

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AS Assignment

Owner name: JAMES RIVER-NORWALK, INC., A CORP OF DELAWARE

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:MONSANTO COMPANY, A CORP OF DE.;REEL/FRAME:004548/0057

Effective date: 19860403

AS Assignment

Owner name: FIBERWEB NORTH AMERICA, INC., 545 NORTH PLEASANTBU

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:JAMES RIVER PAPER COMPANY, INC., A CORP. OF VA;REEL/FRAME:005500/0274

Effective date: 19900403