US3895151A - Non-woven materials - Google Patents

Non-woven materials Download PDF

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Publication number
US3895151A
US3895151A US337465A US33746573A US3895151A US 3895151 A US3895151 A US 3895151A US 337465 A US337465 A US 337465A US 33746573 A US33746573 A US 33746573A US 3895151 A US3895151 A US 3895151A
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web
filaments
woven web
percent
bonded non
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Kenneth Gerald Matthews
John Richardson
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Imperial Chemical Industries Ltd
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Imperial Chemical Industries Ltd
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Priority to US05/546,984 priority Critical patent/US3940302A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • 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
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • 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
    • 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
    • D04H3/153—Mixed yarns or filaments
    • 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
    • D04H3/16—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 filaments produced in association with filament formation, e.g. immediately following extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
    • 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]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material
    • 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]
    • Y10T442/69—Autogenously bonded nonwoven fabric
    • Y10T442/692—Containing at least two chemically different strand or fiber materials

Definitions

  • NoN-WOVEN MATERIALS The invention relates to non-woven materials which have a combination of properties rendering them suitable for use as a primary carpet backing material for tufted carpets.
  • the invention also provides a method for making such materials,
  • a primary carpet backing is required to be as thin as possible, compatible with acceptable tear strength and dimensional stability (which properties should be maintained after tufting, dyeing and application of a secondary backing), since the properties of a tufted carpet depend at least in part on the quantity of service pile. Pile which is inaccessible for use by virtue of being buried in the carpet backing represents a loss of otherwise useful pile yarn to the carpet manufacture.
  • the primary' carpet backing should further be composed of a material which does not stain the pile of the carpet Vwhen wet. It should also preferably be capable of being dyed in the same dye bath as that in which the pile is dyed without the necessity of making special provisions in order to reduce grin through". Again, it should largely retain its tear strength after tufting and also it should be compatible with an adhesive for a secondary backing such as latex.
  • a product being a non-woven web comprising continuous filaments laid in a random serpentine manner and consisting of a blend of homofilaments and bicomponent filaments, percent-65 percent, preferably 35 percent-55 percent of the filaments being bicomponent filaments, said homofilaments consisting of at least partly oriented polypropylene and the bicomponent filaments having two components arranged in a core/sheath relationship, the core component being not less than 3() percent by volume and not more than 8O percent by volume and being composed of at least partly oriented polypropylene, and the sheath being a copolyamide which is capable of being rendered adhesive in pressurised saturated steam at a pressure which leaves the core component substantially unaffected; the said web containing a plurality of equispaced and parallel yarns laid in the lengthwise direction thereof, which yarns are composed of oriented bicomponent continuous filaments having a sheath/core relationship, the sheath component being a copolyamide
  • the homofilaments and bicomponent filaments may be intimately blended throughout the thickness and across the area of the web, but in a preferred embodiment bicomponent filaments are present in a higher concentration at at least one of the surfaces of the product than in the centre of the product.
  • This structure is preferred in carpets since the copolyamide sheath component of the bicomponent filaments can be readily dyed in the same dye-bath as that in which the carpet pile is dyed. whereas polypropylene filaments are less prone to dye-uptake.
  • the preferred structure is less prone to grin through since the number of polypropylene filaments at the surface is reduced.
  • the configuration of the filaments of the web is such that no overall or predominant directional orientation can be discerned.
  • the web should have a uniform filament density.
  • the filaments should be at least partially molecularly oriented and preferably the birefringence of the polypropylene core component and homofilaments should be at least 5() percent of the maximum birefringence.
  • a suitable copolyamide for the sheath component of the bicomponent filaments is that obtained from copolymerising 75 percent by weight hexamethylene adipamide with 25 percent by weight e-caprolactam.
  • the denier of the filaments of the web should preferably be from 5 to 20 denier, more preferably 6 to l0 denier.
  • the equispaced and parallel yarns should be buried within the web thickness but need not be at the mid plane of the web. These yarns provide the product with an exceptional dimensional stability during the severe processing conditions to which to product is subjected during manufacture of a tufted carpet, surprisingly in the widthwise as well as the lengthwise direction.
  • the thickness of the load-bearing component of the bicomponent filaments of which the yarns are formed, that is, the core component, together with the number of such yarns per unit width should be such that the total product contracts in width by no more than 8 percent, preferably by no more than 5 percent when exposed to steam at atmospheric pressure under a load of 225 g per centimetre width of web.
  • the filaments of the product are coated with a water-repellant waxy lubricant.
  • This coating acts as a lubricant for the tufting needles and permits the filaments of the material to be pushed apart to allow the needle to pass through the web, and thereby minimises the chance of filament breakage during tufting with a consequent loss of grab strength and tear strength.
  • the water repellency of the coating limits the penetration of a secondary backing such as latex into the material, and thereby tear strength of the product is maintained to a greater extent than if complete penetration of latex occurred.
  • poly siloxanes act as eminently suitable agents, for example a mixture of 50 percent poly (dimethyl siloxane) with 5U percent poly (methyl hydrogen siloxane) such as that marketed by lmperial Chemical Industries Limited as Silicone Finish M.478.”
  • the coating operation may conveniently be carried out by spraying.
  • the siloxane finish may be supplied for example as a 60 percent aqueous emulsion to a spray gun and in order to ensure rapid polymerisation onto the filament surface.
  • a catalyst may be employed. Conveniently the catalyst may be supplied in aqueous solution or suspension and may be mixed withthe siloxane mixture in the spray gun.
  • the level of finish will generally be greater than 0.5 percent on the material.
  • the siloxanes polymerise to form a cross-linked waxy substance on the surface of each filament and the polymerisation can be accelerated. if desired. by a catalyst.
  • the products of the invention can be prepared by a process whereby a blend of homofilaments and bicomponent filaments are deposited as a web upon a collector surface in a random serpentine manner with a high concentration of bicomponent filaments at the bottom of the web if desired, a warp of threadlines of continuous bicomponent filaments is thereafter laid on top of the non-woven mixture of homofilaments and bicomponent filaments. whereafter a second non-woven layer of a blend of homofilaments and bicomponent fila ments is laid on top of the warp. again. if desired. with a high concentration of bicomponent filaments on the top surface. and the structure thereafter is subjected to a treatment with pressurised saturated steam in a steam chamber fitted with inlet and outlet steam seals. the steam pressure and compacting pressure applied by the seals serving to bond the bicomponent filaments at points of contact.
  • the blend of filaments may be deposited on the collector surface in a random serpentine manner by means of a bank of aspirating jets (air guns) which is traversed in directions normal to the movement of the surface. said guns beingprovided with means to impose an advancing-retarding oscillatory motion upon the filaments in the direction of advance ofthe transversing air gun as they exit from the gun.
  • air guns aspirating jets
  • the first and/or last of the bank of aspirating jets may be adapted to receive and deposit bicomponent filaments in a higher concentration than the remainder of the air guns.
  • the first and/or last air guns may receive and deposit 100% bicomponent filaments.
  • a single spinneret may supply yarn to one or more air guns. and clearly if desired more than one spinneret may be employed. lf the first and/or last air guns are to spray only bicomponent filaments. then these may be either selected from a spinneret pack designed to produce both bcomponent filaments and homofilaments. or from a second spinneret through which only bicomponent filaments are extruded.
  • the yarn structure has no spin finish applied to it. as is necessary' to ensure good separation of the filaments in the aspirating jet. care must be taken to ensure that the tendency for filaments to lick back on the draw-rolls is minimised. We find that this requirement is met if the surfaces of the rolls are knurled or photoetched.
  • the warp of threadlines are supplied from a suitable storage creel. through guide tubes which lead them into the correct positions adjacent to the collector surface.
  • the threadlines should be under sufficient tension to prevent them being deflected by. for example, the air exhaust from the aspirator jet providing the top nonwoven layer. A tension of about 20 g is generally adequate.
  • the structure is bonded in an atmosphere of pressurised saturated steam. the exact pressure depending to some extent upon the exact copolyamide composition from which the sheath of the bicomponent filaments in the non-woven sheet are constituted.
  • the steam pressure will be chosen to give a product having a maximum tear strength
  • another feature which needs to be considered is the selvedge strength. since it is the selvedges which may have to support. on stenter pins. the tufted carpet incorporating the backing of the invention during, for example. the drying process following the scouring and dyeing sequences, ln order to provide a sufficiently strong selvedge ⁇ the bonding pressure may need to be raised somewhat from the pressure required to give optimum tear strength. lf ⁇ ofcourse. the selvedge is to be strengthened in a separate processing step. such as by stitching application of an adhesive. or by bonding the selvedges by a different treatment, then the steam pressure chosen will be that which gives optimum tear strength.
  • the sheath component ofthe bicomponent filaments in the non-woven portion of the product is 'l5/25 hexamethylene adipamide/-caprolactam.
  • the ratio of core to sheath being 40 to 60 by volume and the ratio of polypropylene filaments to bicomponent filaments being 67:33 by number.
  • the filaments having been drawn to a draw ratio of 2.55:l and bonded in a steam oven at a seal pressure of 3.27 Kg ctn2 then we have found that a pressure of l.54 Kg cm2 is necessary to ensure adequate selvedge strength and of L26 Kg crn2 to give optimum tear strength.
  • the non-woven web of the product of the invention is composed entirely of synthetic polymeric materials. there being from l0 percent to 30 percent copolyamide and percent to 7() percent polypropylene based on the total weight of the web. but excluding the polyester/copolyamide reinforcing warp threadlines.
  • FIG. l is a diagrammatic representation of a filter pack and spinneret assembly used in the process of the invention.
  • FlG. 2 is a diagrammatic representation of an air gunfcollector surface device incorporating means to introduce a warp of threadlines.
  • FIG. 3 is a diagrammatic side view of the apparatus used to make the product.
  • a spinneret and filter pack assembly l comprises a spinneret plate 2 containing extrusion orifices 3 and 4.
  • a distributor plate 5 contains orifices 6 which are 'axially aligned with extrusion orifices 3 and 4 and which communicate with a first polymer supply chamber 7.
  • Distributor plate 5 also contains polymer supply ports 8 which communicate with a second polymer supply chamber 9 and a recess l0 formed in the underside of the distributor plate and extending beyond pairs of orifices 4 and 6.
  • the required polymers are metered, in a molten state. into polymer supply chambers 7 and 9 respectively.
  • the polymer from chamber 7, passes through orifices 6 and is extruded through extrusion orifices 3 as homofilaments.
  • Polymer from chamber 9 passes through orifices 8 into recess l0 where it flows around extrusion orifices 4 and is extruded therethrough together with the polymer from orifice 6 as sheath/core bicomponent filaments, the latter polymer forming the core component.
  • a collector surface in the form of an endless belt, which advances in the direction indicated.
  • Air guns 2l, 22 and 23, 24 are mounted on a beam (not shown) which is traversed to and fro above collector 20.
  • Beam is mounted above collector 20 and is supplied with a plurality of threadlines 26 from a storage Creel (not shown), and is provided with means (not shown) whereby threalines 26 can be deposited on collector 20 as a regular warp.
  • Air guns 2l, 22 are fed with a mixture of homofilaments and bicomponent filaments which are laid on the collector 20 as a non-woven web 28.
  • air guns 2l, 22, 23, 24 with means (not shown) to throw the filaments alternatively in ad- Vance and behind the exit nozzle.
  • the warp 29 of threadlines is laid from a plurality of guide tubes (not shown) supplied by beam 25, and are pressed onto the web by presser roll 18, and this in turn is overlaid by a second non-woven web 30 deposited by air guns 23 and 24.
  • air guns 2l and/or 24 will be fed with either a blend of bicomponent filaments and homofilaments with a higher proportion of bicomponent filaments than that supplied to guns 22 and 23 or preferably with bicomponent filaments only.
  • more than one spray gun may be used to spray l00 percent bicomponent filaments.
  • perforated steam pipes 32, 34 are provided immediately upstream of beam 25, and immediately before the web is separated from collector 20.
  • bonding oven 4() (FIG. 3) which comprises a steam chest 4l with inlet and outlet seals 42, 43, wherein the copolyamide component ofthe bicomponent filaments is softened and becomes adhesive.
  • bonding oven 40 On leaving bonding oven 40, the web is compacted by seal 43 and the adhesive sheath component of the bicomponent filament is brought into contact with adjacent filaments whereby' bonds form as the adhesive component hardens.
  • the bonded structure may be treated with a polysiloxane lubricant in lubricant chamber 44.
  • the polysiloxane is pumped in aqueous soluY tion from storage tanks 45, to spray guns 46 and. if necessary therein mixed with a catalyst pumped from storage tank 47.
  • the product may be wound up as roll 48 driven by rolls 49, 50.
  • the two packs producing percent bicomponent filaments feed the last two of the eight spray guns.
  • the filaments separate from each other, and are subjected to a secondary air stream which oscillate the filaments in front of, and be hind, the exit of the gun in the direction of traverse.
  • the speed of traverse of the guns is 55 m/sec and the filaments are thrown alternatively in front of. and behind ⁇ the gun exit at 500 cycles per minute.
  • the eight spray guns are grouped into two sets. each set having 4 guns.
  • the sets are laterally separated by a beam transverse to the collector ⁇ which beam supports a plurality of guide tubes.
  • One end of each tube is positioned a few centimetres above the collector surface and there are lo() such tubes per metre across the entire width of the collector surface.
  • the tubes lead to the vicinity of' a creel in which are stored bobbins of drawn continuous filament yarns.
  • the filaments have a core/- sheath bicomponent structure, the core being poly- (ethylene terephthalate) and the sheath being 66.6 (70/30 w/w) copolyamide. the volume ratio of core of sheath being 50:50.
  • Each tube receives one yarn and guides it to the vicinity of the collector surface.
  • a bottom web is laid by the guns upsteam of the crossbeam. and is treated with atmospheric steam to discharge static electricity from the web before passage under the cross beam.
  • the yarns are pressed onto the surface of the web laid by the set of spray guns situated upsteam from the cross-beam. by passage of the threads under a presser roll, ln this way a warp of parallel threadlines is laid on the bottom web. there being l60 threads per metre. This structure is finally overlaid by the web sprayed by the downstream set of spray guns.
  • the width of the web is 4 m and its weight is
  • the web is treated with atmospheric steam to aid removal from the wire mesh conveyor and is then bonded by passage through a steam chamber 0.3 m long whilst sandwiched between two fabric conveyor belts.
  • the steam chamber has inlet and outlet steam seals consisting of inflatable air bags as described in British Patent specification No. 1,001,508 which have a compacting action on the web.
  • An air pressure of 3.30 Kg cm2 is maintained in the seals and saturated steam at a pressure of 1.54 Kg crri-2 is maintained in the steam chamber under which conditions the copolyamide sheaths of the bicomponent filaments in the structure soften and bonds are formed between contiguous bicomponent filaments.
  • a poly-siloxane lubricant is sprayed onto the web.
  • the lubricant is a mixture of approximately equal parts of poly(dimethyl siloxane) and poly(methyl hydrogen siloxane) in an aqueous emulsion, there being 60 percent by weight of siloxanes in the emulsion.
  • the emulsion is pumped to spray guns and a commercial catalyst (manufactured by Imperial Chemical Industries Ltd., as EP 5865) in aqueous suspension is mixed with the emulsion immediately before spraying.
  • the spray is adjusted to give l percent of siloxane on the material.
  • the untufted web had grab strengths of 42 and 52 Kg in the machine and cross-machine direction respectively.
  • the web was tufted using an Ellison tufting machine to give 2.6 tufts per cm both in the machine and cross-machine direction.
  • the tufted material was winch dyed and dried in a Stcnter at 140C. At this stage, the tufted fabric had a selvedge strength of 37 Kg.
  • the width contraction occurring in atmospheric steam Examples were measured as follows.
  • SELV EDGE STRENGTH Measured similarly on a sample taken from the Selvedge, but with stenter pins being used in place of the lower clamp.
  • Example 7 the products, apart from the 100 percent heterofllament product (Example 7), had ⁇ good properties before and after tufting and dyeing.
  • Example 2 was inferior to the other examples because of its low Selvedge Strength and because the The parameters referred to in this and the following selvedge had bulked up during the dyeing step.
  • a bonded non-woven web comprising continuous filaments laid in a random serpentine manner and consisting of a blend of homofilaments and bicomponent filaments, percent-65 percent ofthe filaments being bicomponent filaments, said homofilaments consisting of at least partly oriented polypropylene and said bicomponent filaments having two components arranged in a core/sheath relationship, the core component being not less than percent by volume and not more than 80 percent by volume and being composed of at least partly oriented polypropylene, and the sheath being a copolyamide which is capable of being rendered adhesive in pressurized saturated steam and which has a melting point higher than that of the core component; the said web containing a plurality of equispaced and parallel yarns laid in the lengthwise direction thereof, which yarns are composed of oriented bicomponent continuous filaments having a core/sheath relationship, the sheath component being a copolyamide which can be rendered adhesive in pressurized saturated steam at the pressure required to render the sheath component of the
  • a bonded non-woven web as claimed in claim l wherein the bicomponent filaments comprising the non-woven web are present in a higher proportion in at least one of the surfaces of the web than in the centre of' the web.
  • a bonded non-woven web as claimed in claim l wherein the birefringence of the polypropylene core component of the bicomponent filaments of which the non-woven web is composed and of the polypropylene homofilaments is at least 50 percent of the maximum birefringence.
  • a bonded non-woven web as claimed in claim l wherein the denier of the filaments of the web is between 5 and 20 denier.
  • a bonded non-woven web as claimed in claim l wherein the core component of the bicomponent filaments of the equispaced and parallel yarns is polyethylene terephthalate.
  • a bonded non-woven web as claimed in claim l wherein the core component of the bicomponent filaments of the equispaced and parallel yarns is a polyamide.
  • a bonded non-woven web as claimed in claim l wherein there are at least equispaced and parallel yarns per metre (measured in the crosswise direction).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Carpets (AREA)
US337465A 1972-03-02 1973-03-02 Non-woven materials Expired - Lifetime US3895151A (en)

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GB980372A GB1406252A (en) 1972-03-02 1972-03-02 Non-woven materials and a method of making them
AU52940/73A AU473978B2 (en) 1972-03-02 1973-03-06 Nonwoven material suitable for carpet backing
JP48028111A JPS519066B2 (de) 1972-03-02 1973-03-12

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AU (1) AU473978B2 (de)
BE (1) BE796244A (de)
CA (1) CA1006768A (de)
CH (1) CH564116A5 (de)
DE (1) DE2310542A1 (de)
FR (1) FR2174290B1 (de)
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Cited By (28)

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US4071647A (en) * 1973-05-08 1978-01-31 The Goodyear Tire & Rubber Company Rubber goods
US4086381A (en) * 1977-03-30 1978-04-25 E. I. Du Pont De Nemours And Company Nonwoven polypropylene fabric and process
US4112037A (en) * 1977-01-31 1978-09-05 Albany International Corp. Process of making air filter fabric
US4154357A (en) * 1977-02-23 1979-05-15 Imperial Chemical Industries Limited Fibrous structures
US4729371A (en) * 1983-10-11 1988-03-08 Minnesota Mining And Manufacturing Company Respirator comprised of blown bicomponent fibers
US4756942A (en) * 1986-09-18 1988-07-12 Vitapharm Basel Ag Elastic fabric
US4795668A (en) * 1983-10-11 1989-01-03 Minnesota Mining And Manufacturing Company Bicomponent fibers and webs made therefrom
US5336552A (en) * 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
US5382400A (en) * 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) * 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5424115A (en) * 1994-02-25 1995-06-13 Kimberly-Clark Corporation Point bonded nonwoven fabrics
US5534339A (en) * 1994-02-25 1996-07-09 Kimberly-Clark Corporation Polyolefin-polyamide conjugate fiber web
US5605739A (en) * 1994-02-25 1997-02-25 Kimberly-Clark Corporation Nonwoven laminates with improved peel strength
US5643662A (en) * 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
WO2000012800A2 (en) * 1998-08-27 2000-03-09 Colbond B.V. Nonwoven backing and carpet comprising same
US6136436A (en) * 1996-08-23 2000-10-24 Nyltec Inc. Soft silky large denier bicomponent synthetic filament
EP1154707A1 (de) * 1999-02-17 2001-11-21 Filtrona Richmond Limited Verfahren und apparat zum spinnen eines netzes aus gemischten fasern sowie daraus hergestellte produkte
US6352948B1 (en) 1995-06-07 2002-03-05 Kimberly-Clark Worldwide, Inc. Fine fiber composite web laminates
US20020125601A1 (en) * 2001-03-09 2002-09-12 Allen Martin A. Apparatus and method for extruding single-component liquid strands into multi-component filaments
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith
US6565344B2 (en) 2001-03-09 2003-05-20 Nordson Corporation Apparatus for producing multi-component liquid filaments
US20030168153A1 (en) * 2000-08-21 2003-09-11 Ouellette William Robert Surface bonded entangled fibrous web and method of making and using
US20040137211A1 (en) * 2000-08-21 2004-07-15 Ouellette William Robert Entangled fibrous web of eccentric bicomponent fibers and method of using
US20040253888A1 (en) * 2001-10-11 2004-12-16 Carel Iedema Nonwoven sheeting having tailor-made, non uniform properties
US20080210363A1 (en) * 2005-05-25 2008-09-04 Reifenhauser Gmbh & Co. Maschinenfabrik Process and apparatus for manufacturing spun-bonded fabric
WO2014016172A1 (en) * 2012-07-26 2014-01-30 Bonar B.V. Primary carpet backing and tufted carpet comprising the same
US20220333300A1 (en) * 2019-09-20 2022-10-20 Aladdin Manufacturing Corporation Recyclable tufted carpet product
US12123121B2 (en) 2018-05-29 2024-10-22 Aladdin Manufacturing Corporation Method for manufacturing a carpet or a rug and a carpet or rug obtained thereby

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GB2121847B (en) * 1982-06-14 1986-04-30 Bondina Limited Adhesive webs and their production
GB2143867A (en) * 1983-07-26 1985-02-20 Shirley Inst The Three-dimensional textile structures
US4666763A (en) * 1984-12-07 1987-05-19 Akzona Incorporated Fiber batts and the method of making
GB8916373D0 (en) * 1989-07-18 1989-09-06 Simon Container Mach Ltd A heat transfer system
FR2657893B1 (fr) * 1990-02-08 1993-04-02 Rhone Poulenc Fibres Nontisses de filaments continus synthetiques dont au moins une partie a proprietes de surface modifiees, procede pour leur fabrication et leurs applications.
WO2019067432A1 (en) * 2017-09-27 2019-04-04 Georgia-Pacific Nonwovens LLC NON-WOVEN TWO-COMPONENT FIBER MATERIAL WITH HIGH CORE

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US3563838A (en) * 1968-07-09 1971-02-16 Du Pont Continuous filament nonwoven web
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US3338992A (en) * 1959-12-15 1967-08-29 Du Pont Process for forming non-woven filamentary structures from fiber-forming synthetic organic polymers
US3502763A (en) * 1962-02-03 1970-03-24 Freudenberg Carl Kg Process of producing non-woven fabric fleece
US3276944A (en) * 1962-08-30 1966-10-04 Du Pont Non-woven sheet of synthetic organic polymeric filaments and method of preparing same
US3511747A (en) * 1963-03-01 1970-05-12 British Nylon Spinners Ltd Bonded textile materials
US3551271A (en) * 1964-07-30 1970-12-29 British Nylon Spinners Ltd Nonwoven fabrics containing heterofilaments
US3449187A (en) * 1964-12-08 1969-06-10 Bobkowicz E Method and apparatus for making nonwoven fabrics
US3719546A (en) * 1968-03-14 1973-03-06 Bigelow Sanford Inc Lubricated non-woven fabric
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Cited By (38)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4071647A (en) * 1973-05-08 1978-01-31 The Goodyear Tire & Rubber Company Rubber goods
US4112037A (en) * 1977-01-31 1978-09-05 Albany International Corp. Process of making air filter fabric
US4154357A (en) * 1977-02-23 1979-05-15 Imperial Chemical Industries Limited Fibrous structures
US4086381A (en) * 1977-03-30 1978-04-25 E. I. Du Pont De Nemours And Company Nonwoven polypropylene fabric and process
US4729371A (en) * 1983-10-11 1988-03-08 Minnesota Mining And Manufacturing Company Respirator comprised of blown bicomponent fibers
US4795668A (en) * 1983-10-11 1989-01-03 Minnesota Mining And Manufacturing Company Bicomponent fibers and webs made therefrom
US6057256A (en) * 1983-10-11 2000-05-02 3M Innovative Properties Company Web of biocomponent blown fibers
US4756942A (en) * 1986-09-18 1988-07-12 Vitapharm Basel Ag Elastic fabric
US5382400A (en) * 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5418045A (en) * 1992-08-21 1995-05-23 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric
US5405682A (en) * 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5336552A (en) * 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
US5643662A (en) * 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith
US5424115A (en) * 1994-02-25 1995-06-13 Kimberly-Clark Corporation Point bonded nonwoven fabrics
US5534339A (en) * 1994-02-25 1996-07-09 Kimberly-Clark Corporation Polyolefin-polyamide conjugate fiber web
US5605739A (en) * 1994-02-25 1997-02-25 Kimberly-Clark Corporation Nonwoven laminates with improved peel strength
US6352948B1 (en) 1995-06-07 2002-03-05 Kimberly-Clark Worldwide, Inc. Fine fiber composite web laminates
US6136436A (en) * 1996-08-23 2000-10-24 Nyltec Inc. Soft silky large denier bicomponent synthetic filament
US6207599B1 (en) 1998-08-27 2001-03-27 Akzo Nobel Nv Nonwoven backing and carpet comprising same
WO2000012800A3 (en) * 1998-08-27 2000-06-15 Akzo Nobel Nv Nonwoven backing and carpet comprising same
WO2000012800A2 (en) * 1998-08-27 2000-03-09 Colbond B.V. Nonwoven backing and carpet comprising same
EP1154707A1 (de) * 1999-02-17 2001-11-21 Filtrona Richmond Limited Verfahren und apparat zum spinnen eines netzes aus gemischten fasern sowie daraus hergestellte produkte
EP1154707B1 (de) * 1999-02-17 2017-06-07 Essentra Porous Technologies Corp. Poröser stab
US20040137211A1 (en) * 2000-08-21 2004-07-15 Ouellette William Robert Entangled fibrous web of eccentric bicomponent fibers and method of using
US20030168153A1 (en) * 2000-08-21 2003-09-11 Ouellette William Robert Surface bonded entangled fibrous web and method of making and using
US7128789B2 (en) * 2000-08-21 2006-10-31 The Procter & Gamble Company Surface bonded entangled fibrous web and method of making and using
US6814555B2 (en) 2001-03-09 2004-11-09 Nordson Corporation Apparatus and method for extruding single-component liquid strands into multi-component filaments
US6565344B2 (en) 2001-03-09 2003-05-20 Nordson Corporation Apparatus for producing multi-component liquid filaments
US7001555B2 (en) 2001-03-09 2006-02-21 Nordson Corporation Apparatus for producing multi-component liquid filaments
US20030180407A1 (en) * 2001-03-09 2003-09-25 Nordson Corporation Apparatus for producing multi-component liquid filaments
US20020125601A1 (en) * 2001-03-09 2002-09-12 Allen Martin A. Apparatus and method for extruding single-component liquid strands into multi-component filaments
US20040253888A1 (en) * 2001-10-11 2004-12-16 Carel Iedema Nonwoven sheeting having tailor-made, non uniform properties
US20080210363A1 (en) * 2005-05-25 2008-09-04 Reifenhauser Gmbh & Co. Maschinenfabrik Process and apparatus for manufacturing spun-bonded fabric
US7922849B2 (en) * 2005-05-25 2011-04-12 Reifenhauser GmbH & Co. KG. Maschinenfabrik Process and apparatus for manufacturing spun-bonded fabric
WO2014016172A1 (en) * 2012-07-26 2014-01-30 Bonar B.V. Primary carpet backing and tufted carpet comprising the same
US12123121B2 (en) 2018-05-29 2024-10-22 Aladdin Manufacturing Corporation Method for manufacturing a carpet or a rug and a carpet or rug obtained thereby
US20220333300A1 (en) * 2019-09-20 2022-10-20 Aladdin Manufacturing Corporation Recyclable tufted carpet product

Also Published As

Publication number Publication date
JPS49117772A (de) 1974-11-11
DE2310542A1 (de) 1973-09-06
FR2174290A1 (de) 1973-10-12
FR2174290B1 (de) 1977-02-04
BE796244A (fr) 1973-09-03
AU473978B2 (en) 1974-09-12
NL7302972A (de) 1973-09-04
GB1406252A (en) 1975-09-17
CA1006768A (en) 1977-03-15
JPS519066B2 (de) 1976-03-23
CH564116A5 (de) 1975-07-15
AU5294073A (en) 1974-09-12

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