WO2003029541A1 - Formes moulables a haute performances non tissees, tissees ou tricotees - Google Patents

Formes moulables a haute performances non tissees, tissees ou tricotees Download PDF

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Publication number
WO2003029541A1
WO2003029541A1 PCT/US2002/031255 US0231255W WO03029541A1 WO 2003029541 A1 WO2003029541 A1 WO 2003029541A1 US 0231255 W US0231255 W US 0231255W WO 03029541 A1 WO03029541 A1 WO 03029541A1
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WO
WIPO (PCT)
Prior art keywords
fibers
filaments
web
melt processable
perfluoropolymer
Prior art date
Application number
PCT/US2002/031255
Other languages
English (en)
Inventor
Gary Stanitis
Frank Cistone
Jin Choi
Original Assignee
Xtreme Fibers, Inc.
Lantor, Inc.
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Filing date
Publication date
Application filed by Xtreme Fibers, Inc., Lantor, Inc. filed Critical Xtreme Fibers, Inc.
Publication of WO2003029541A1 publication Critical patent/WO2003029541A1/fr

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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
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/247—Mineral
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • 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
    • 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
    • D04H3/10—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 yarns or filaments made mechanically
    • D04H3/105—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 yarns or filaments made mechanically by needling
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D10B2101/06—Glass
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D10B2101/08—Ceramic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/20—Metallic fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/04—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons
    • D10B2321/042—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons polymers of fluorinated hydrocarbons, e.g. polytetrafluoroethene [PTFE]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/06—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers
    • D10B2331/061—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers polyetherketones, polyetheretherketones, e.g. PEEK
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/14—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensates of cyclic compounds, e.g. polyimides, polybenzimidazoles
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/30—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14
    • D10B2331/301—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14 polyarylene sulfides, e.g. polyphenylenesulfide

Definitions

  • This invention relates to novel, high performance nonwoven, woven, and knit products, which can be formed into shapes through standard industry practices such as thermoforming, molding, and drawing using heat, pressure, vacuum and a combination of the same.
  • the nonwoven, woven, and knit products may contain any combination of high performance, chemically resistant, temperature resistant fibers, but in all cases include a melt processable perfluoropolymer fiber, which acts as a binder.
  • the binder fiber either fully or partially melts during the molding or forming process, adhering to the other fibers present. Upon cooling the fully or partially molten binder fiber re-solidifies, locking the other fibers into position, allowing the nonwoven, woven, or knit product to retain the molded or formed shape.
  • the binder fiber allows the ability to mold and form the roll good into a shape (roll good being a common industry term to refer to woven, nonwoven, and knit fabric and webs).
  • roll good being a common industry term to refer to woven, nonwoven, and knit fabric and webs.
  • the adhesion of the perfluoropolymer binder fiber to the other fibers also imparts other benefits, including improved strength, improved dimensional stability, resistance to deformation due to forces such as pressure drop, gravity, and mechanical stress, the potential for a more open and loftier structure leading to lower weight, resistance to compression, and a softer, more cushioned feel.
  • the perfluoropolymer fiber may be in a variety of forms such as homofilament, bicomponent, and multicomponent, as well as shapes such as circular, multilobal, segmented, sheath/core, hollow, islands in the sea, micro fibers, and other common shapes used in the industry. It may also be made in a variety of processes such as melt spinning, spun bonding and melt blowing. Due to the high temperature resistance, extreme chemical resistance, and low flammability of melt processable perfluoropolymer fibers, high performance fabrics and webs for filtration, electronics, protective clothing, battery and fuel cell components, medical, aerospace and other applications which incorporate high performance fibers will maintain their performance under severe service conditions. Objectives of the Invention
  • An objective of this invention to provide nonwoven, woven, and knit roll goods that can be used in severe environments (referred to as high performance), which are formable and moldable, and will maintain their shape or form in service conditions.
  • melt processable perfluoropolymer fibers such as Teflon®, Profilen®, Rastex®, and Toyoflon®
  • PTFE polytetrafluoroethyene
  • the fabric or web is made in such a way as to contain either a blend of two or more melt processable perfluoropolymer fibers with distinct melting or softening points, or a conjugated fiber, such as sheath/core, side by side, islands in the sea, segmented pie, or the like, made from two, or more, separate melting point melt processable perfluoropolymers.
  • the ability to obtain a large amount of crimp allows this type of nonwoven to be drawn deeply during the molding and/or forming process.
  • Many high performance fibers are not melt processable and so cannot be easily molded, formed, or fused.
  • the incorporation of melt processable perfluoropolymer fibers, which are themselves high performance, overcomes this problem without sacrificing performance characteristics of the roll good.
  • Still another objective of this invention to provide high performance nonwoven formable and moldable roll goods containing melt processable perfluoropolymer fibers that have a variety of beneficial properties.
  • the molded or formed items can be more easily incorporated into a complex part geometry, can be lighter weight due to a more open structure, resist compressive force, have improved dimensional stability, have more cushion and a softer feel, and resist shape deterioration due to forces, such as pressure drop, during their service life.
  • the formable, moldable high performance roll goods can be used by themselves or incorporated into a composite or laminate structure. Background
  • nonwoven roll goods The market for nonwoven roll goods is large and growing due to a number of reasons.
  • technologies include felting and needled felting, wet laying, air laying, spun bonding, and melt blowing. Additional product enhancements can be made with down stream processes such as calendaring, hydro-entangling, air entangling, singeing, coating, and impregnating to name a few.
  • the fibers used to make nonwoven products are widely varied, based on many different families of polymers (some examples are: polyesters, polyamides, polyimides, aromatic polyamides, polyolefins, acrylics, and fiuoropolymers).
  • the fibers themselves can take many forms including circular, oval, multilobal, sheath/core, hollow, islands in the sea, segmented.
  • the individual fibers may also be a single polymer (homofilament), or be made from two or more polymers (bicomponent and multicomponent).
  • nonwovens are a growing market. This growth of nonwovens is further ensured due to the fact that they tend to be lower cost to produce in many cases than woven and knit textiles suitable for the same application.
  • One of the technologies applied to nonwoven roll goods to further improve their value and performance is the ability to make them moldable.
  • United States Patent 6,165,921 to Negata et al discusses a number of approaches taken to make a nonwoven roll good suitable for moldable automotive acoustical insulation.
  • the patent discusses historical approaches to this such as impregnation of a nonwoven fabric with a phenolic resin binder, the addition of a powdered resin binder, and the addition of thermoplastic fibers with different (low) melting points as the preferred embodiment.
  • United States Patent 5,646,077 to Matsunaga et al also describes a process to make a fusible nonwoven polyester fabric suitable for cushioning which is soft and resistant to flattening.
  • Matsunaga describes both the use of low melting homofilament binder fibers, and the preferred approach of using conjugated fibers of the sheath core variety with a polyester core and a binder polymer as the sheath.
  • the nonwoven is treated with pressure and high temperature to cause the binder fiber to melt and fuse to the surrounding bulk fibers.
  • United States Patent 4,830,900 to Sumii et al describes a procedure to impregnate a nonwoven fabric with a binder and adhering the impregnated nonwoven to a base sheet. The resulting article "can be easily subjected to molding such as deep drawing.".
  • United States Patent 5,298,319 to Donahue et al reveals a moldable composite structure suitable for automotive trunk liners.
  • the three layer composite consists of a top, nonwoven layer, a middle layer made of an extruded thermoformable material, and a bottom layer consisting of a nonwoven.
  • the nonwoven fabric is comprised of polypropylene fibers.
  • United States Patent 4,581,272 to Walters et al discusses decorative automotive kick panels "...comprised of a molded textile substrate including thermo-plastic fibers which are at least partially heat fused together;”.
  • the textile described is made from fibers of polyolefin, polyethylene, and/or polyester. Heat and pressure are applied to form the article into a shape. The resulting finished article has good shape retention and dimensional stability.
  • United States Patent 5,565,259 to Juriga a contoured automotive interior insulating panel is described.
  • the composite article includes a cloth or vinyl surface, and a substrate lamina.
  • the substrate lamina includes a foam lamina and a reinforcing scrim. Because the article is molded into a shape it is important that "...the fibers [in the polyester scrim fabric] are crimped to better bridge deep drawn areas as the laminate is formed into a contoured shape."
  • United States Patent 5,939,342 describes the use of a moldable nonwoven such as a spun bonded fabric made from a blend of polyester and polypropylene fibers bonded to a facing material. The spun bonded fabric replaces polyurethane and polypropylene foams due to lower cost and having aesthetically pleasing characteristics.
  • United States patent 5,558,689 to Yanagihara et al describes filter elements used to filter dust and dirt in gas streams.
  • the filter elements of the invention are mechanically supported in a corrugated geometry.
  • the supported corrugated structure prevents the mechanical degradation of the filter elements due to negative pressure during use, and from mechanical vibration or pack pulsing during cleaning.
  • the filtration media woven or nonwoven fabric
  • the filtration media can be formed into a corrugated shape before assembly, making it easier to insert and position inside the corrugated support structure. He proposes four methods to allow the fabric to be formed. One is the use of an adhesive applied to the fabric. A second is the use of a powdered low melting polymer blended onto the fabric. A third method is to use low melting fibers in the fabric construction. A fourth, preferred method is to use heat to shrink the fabric causing it to take on a corrugated shape.
  • Yangihara's suggestion to use a binder or low melting polymer powder or fiber as a method to mold the filter article will limit the temperature performance and chemical resistant characteristics of the filter media due to the presence of the low melting binder or polymer.
  • Yangihara gives no specific recommendation as to what type of low melting polymer to use as a powder or fiber, and certainly does not reveal any high performance melt processable fiber which could be used as a binder for higher performance fabrics made from materials like PTFE, polyimide and polyphenylene sulfide.
  • Yangihara relies solely on the corrugated mechanical support structure to mechanically stabilize the filter media, and does not teach that dimensional stability, resistance to compressive force, and resistance to shape deterioration due to pressure drop and mechanical vibration can be enhanced when a high performance melt processable fiber is used as a binder fiber without sacrificing chemical, temperature, and flame resistance.
  • This invention provides woven, knit, and non-woven fabrics which include continuous multifilament yarns and/or staple fibers and/or fibrous webs made at least in part from melt processable perfluoropolymers, such as those disclosed and claimed in published PCT application PCT/USOO/23920, with these melt processable perfluoropolymers in the resulting fabric or web according to the invention acting as a binder.
  • melt processable perfluoropolymers such as those disclosed and claimed in published PCT application PCT/USOO/23920
  • fibers made from melt processable perfluoropolymers can be easily incorporated as blends into woven, knit, and nonwoven fabrics and webs containing predominantly high performance fibers such as PTFE, polyimide, aramid, polyether ether ketone, polyether ketone, polyphenylene sulfide, glass, carbon fibers, and other high performance fibers.
  • high performance fibers such as PTFE, polyimide, aramid, polyether ether ketone, polyether ketone, polyphenylene sulfide, glass, carbon fibers, and other high performance fibers.
  • melt processable fibers used can vary widely in form and structure. They can be homofilament or multicomponent containing two or more types of melt processable perfluoropolymer (different melting points, different molecular weight, and different chemistries).
  • the fibers can be circular, segments, multilobal, hollow, and micro fibers. They can also be conjugated fibers, such as sheath/core, islands in the sea, side-by-side, segmented pie, and the like.
  • the fibers can be made by a variety of processes, including melt spinning, spun bonding, and melt blowing.
  • melt processable perfluoropolymers with high performance fibers which include melt processable perfluoropolymers with different melting point
  • fabrics and webs that are easier to incorporate into assembles or complex geometric structures lower density fabrics and webs due to a more open structure, fabrics that resist compressive force, fabrics and webs with improved dimensional stability, fabrics and webs with more cushion and softer feel.
  • the fabrics and webs can be used as is or incorporated into a composite or laminate structure.
  • This invention relates to the use of continuous multifilament yarns, staple fibers, and fibrous webs made from melt processable perfluoropolymers in woven, knit, and nonwoven fabrics.
  • Melt processable perfluoropolymers are those, which can be melted and processed like most conventional plastics.
  • This invention is suitable for all melt processable perfluoropolymers, which are typically made from tetrafluoroethylene (TFE) monomer with one or more additional or modifying monomers.
  • TFE tetrafluoroethylene
  • the most common modifying monomers are perfluoro vinyl ethers including methyl, ethyl, and propyl vinyl ethers, hexafluoropropylene, perfluorinated butene, pentene, and heptene, cyclic perfluorinated dioxoles, as well as other fluorinated modifying monomers possibly containing also hydrogen and/or chlorine atoms as described in United States Patent 4,675,380.
  • the amount of modifying monomer or monomers present in the polymer can range from about 0.5 to 20 mole% and are typically 1 to 10 mole%, but can be higher.
  • moldable fabrics There have been many approaches to this technology, most involving the use of an adhesive or resin binder, or a low melting additive such as a powder or a fiber. Other approaches have also been used, such as lamination to a moldable foam or sheet.
  • the patent literature in this area is limited to fabrics and webs that are based on low or moderate performance fibers. The reason being that the overall performance of the moldable fabric is limited by the lowest performance material present.
  • a low melting resin, adhesive, or polymer powder or fiber is used as the binder, the chemical and temperature resistance of the fabric or web is limited to the performance characteristics of the binder. So, moldable fabrics and webs are predominately used in low to moderate performance environments, such as automotive interiors, decorative fabrics, and industrial applications such as filtration where low to moderate temperatures are involved and harsh chemicals are not used.
  • melt processable perfluoropolymer fibers are themselves very a higher performance material. They are very high melting and have good thermal resistance up to 250° to 260° C, are resistant to most industrial chemicals even at elevated temperatures, are very resistant to burning and flame propagation (oxygen index greater than 95), have very high dielectric strength, and have very high purity.
  • the unique combination of their high performance characteristics, yet their ability to be melted, is unique and allows for the unexpected ability to use them as a binder fiber in high performance fabrics and webs, and obtain moldability and formability without sacrificing performance.
  • melt processable perfluoropolymer binder fibers In many cases it is desirable for the melt processable perfluoropolymer binder fibers to be undrawn or unoriented (UOY).
  • UOY unoriented
  • the advantage of an undrawn binder fiber is that it tends to shrink less when heated near, or above its melting point. The reduced tendency for the fibers to shrink allows them to melt and distribute evenly onto the other fibers in the matrix without causing the web or fabric to retract or deform. It is possible to use partially or fully oriented melt processable perfluoropolymer fibers as a binder, but the fabric must be properly constrained during the thermal treatment process.
  • binder fiber can be incorporated.
  • One process is carding and needling to produce what is called a needled felt.
  • Melt processable perfluoropolymer fibers are crimped with a suitable number of crimps per inch (typically 4 to 20) and cut to a suitable length for carding (typically 2.5 to 5 inches).
  • a wide range of deniers, or blends of deniers can be used, typically, but not limited to, 1 to 10 denier per filament.
  • the melt processable perfluoropolymer binder fibers are mixed with the one or more other high performance f ⁇ ber(s) such as PTFE, polyimide, aramid, polyether ether ketone, polyether ketone, polyphenylene sulfide, glass, carbon, and higher melting melt processable perfluoropolymer fibers.
  • the fibers are mixed either before, during, or just after the opening process, prior to being carded.
  • the mixed fibers are fed to the card, which has been adjusted to accept the characteristics of the fiber blend. Additionally, some methods, such as humidity or ionized air may be used to reduce static. Any blend ratio may be used, although it is typical to use 5 to 60% by weight of binder fiber.
  • the melt processable perfluoropolymer binder fibers are produced from a melt processable perfluoropolymer with an appropriate melting point to allow thermal molding with the other fibers present, typically 200 to 320° C.
  • the melt processable perfluoropolymer fiber is chosen so that the felt can be molded at a temperature above its melting point, but below the decomposition or deformation point of the other high performance fibers present.
  • the carded web is lapped and needled to give the appropriate physical properties.
  • a reinforcing scrim may also be inserted prior to needling.
  • a melt processable perfluoropolymer fiber with a melting point of between 260° and 315° C is used.
  • the amount and amplitude of crimp, as well as the residual elongation of both the melt processable perfluoropolymer fibers and the other high performance fibers can be adjusted during their manufacture to provide the optimum amount of draw ability in the felt during forming.
  • a scrim When a scrim is used it is preferable if the scrim is crimped to allow it to be better formed or molded.
  • the scrim should also be made from a high performance fiber.
  • the fiber blend ratio may be uniform throughout the web, or may be varied throughout the felt cross section, even to the extent that some layers are 100% melt processable perfluoropolymer fibers while others may be 100%) other high performance fibers.
  • the variation in cross section can be adjusted so as to achieve the desired performance characteristics from the felt.
  • the resulting felt can be used as is, or laminated to other materials, including non-fabric components such as foams, sheets, and films, to form a composite structure.
  • the melt processable perfluoropolymer binder fibers can be homofilament or multicomponent containing two or more types of melt processable perfluoropolymer (different melting points, different molecular weight, and different chemistries).
  • the fibers can be circular, segments, multilobal, hollow, and micro fibers. They can also be conjugated fibers, such as sheath/core, islands in the sea, side-by-side, segmented pie, and the like.
  • the fibers can be made by a variety of processes, including melt spinning, spun bonding, and melt blowing.
  • Melt processable perfluoropolymer fibers can also be combined with other high performance fibers in nonwovens other than carded, needled felts, such as in air- laying and wet-laying processes.
  • the amount of crimp, length of fibers, residual elongation, and fiber denier must be adjusted so as to be suitable for these other process technologies. Fiber blend ratios and melting point differences must also be optimized as described above.
  • Another method to produce a formable high performance fabric is to use staple fibers having a bicomponent or multicomponent structure, such as sheath/core, side- by-side, or segmented.
  • One component is a lower melting melt processable perfluoropolymer and the other component is a higher melting melt processable perfluoropolymer.
  • sheath/core fibers the lower melting polymer would be in the sheath.
  • the lower melting point polymer ideally should make up 5 to 60 weight % of the bi or multicomponent fiber.
  • the fibers are crimped to a high amplitude and cut to suitable length for making a carded, needled felt as described above.
  • the fibers can be flat (no crimp) and cut short (0.1 to 1 inch) in length and be used in a wet-laying process.
  • the fiber can be cut to be suitable for, and converted to a nonwoven fabric using an air-laying process. Webs produced from each of these processes are capable of being molded and formed using heat, pressure and/or vacuum. These webs can be used by themselves or combined with other layers into a composite structure.
  • a high performance moldable fabric by either spun bonding or melt blowing two or more melt processable perfluoropolymers fiber streams onto a common take up apparatus, making a web with a mixture of two or more melt processable perfluoropolymers, each having a separate melting point, typically 10° to 100° C apart.
  • the lower melting point polymer ideally should make up 5 to 60 weight % of the bi or multicomponent fiber.
  • the fiber geometries can be circular, segments, multilobal, hollow, and micro fibers. They can also be conjugated fibers, such as sheath/core, islands in the sea, side-by-side, segmented pie, and the like.
  • the resulting webs can be molded and formed as described previously.
  • melt processable perfluoropolymer continuous filament yarns can also be either blended with other high performance yarns, or woven or knit with other high performance yarns into fabrics.
  • melt processable perfluoropolymer staple fibers can be blended and twisted with other high performance staple fibers to make a blended spun yam and then woven or knit into a fabric.
  • a wide range of weave and knit structures are possible.
  • the resulting woven and knit fabrics can be formed with heat and pressure.
  • any of the woven, knit, or nonwoven fabrics and webs described above can be molded, drawn, or formed into shape by common industry practice.
  • the fabric is preheated in an oven, often a hot air circulating oven with radiant heaters.
  • the fabric is heated to a temperature above the softening point of the lower melting melt processable perfluoropolymer fibers (between 5° and 50° C above their melting point) and below the melting, decomposition or deformation point of the other high performance fibers present (usually 5° to 50° C below the melting, decomposition or deformation point). In many cases this temperature will be between 275° and 350° C.
  • the fabric is then held at this temperature for 1 to 5 minutes to allow the fabric or web to reach thermal equilibrium.
  • the article After the article has been preheated it is placed into a molding device, typically between two match set dies.
  • the dies may be heated to prevent the fabric or web from cooling during the molding process.
  • vacuum may be applied to one side to position and shape the fabric or web.
  • Pressure is applied to one or both sides of the mold to force the fabric into the proper shape with the proper thickness.
  • the mold is then cooled, either naturally or by passing a cooling medium through a cavity within it. When the mold is opened and the fabric or web removed, the fabric or web will have taken the shape or form of the mold.
  • This description is one type of industrial molding process, but any molding process suitable of reaching the necessary temperature and pressure can be used with high performance moldable fabrics and webs taught here.
  • the thermal treating process can be used specifically to cause the fabric or web to form and retain a more complex shape.
  • the thermal process may also be used, not to form a complex shape, but to cause fiber to fiber adhesion, imparting many benefits.
  • the benefits include improved strength, improved dimensional stability, resistance to deformation due to forces such as pressure drop, gravity, and mechanical stress, a more open and loftier structure leading to lower weight, resistance to compression, and a softer, more cushioned feel.
  • simpler processes such as hot calendaring or hot air ovens (either continuous or batch), may be used to thermally treat the fabric or roll good, causing fiber to fiber adhesion to occur.
  • the microstrucrure of the fabric or web Prior to the heating and molding process the microstrucrure of the fabric or web shows individual entangled fibers with no adhesion.
  • the melt processable perfluoropolymer fibers either fully or partially melt and fuse to the surrounding fibers (in the case of a web or fabric made with 100% melt processable perfluoropolymers fibers, but with two different melting point fibers or portions of fibers, it is the lower melting point perfluoropolymer fibers or portions of fibers that melts and fuses).
  • the fabric or web After heating and molding the fabric or web has a microstrucrure where it can be seen that the melt processable perfluoropolymer has adhered to and bonded with the other fibers present.
  • the fiber to fiber adhesion developed after thermal treatment can improve the overall mechanical properties and dimensional stability, possibly reducing the amount of scrim needed.
  • Perfluoropolymer and other higher performance fiber scrims are expensive and any reduction in the weight of the scrim needed in the felt has a positive economic benefit. It is also possible to needle the carded web less, which produces a loftier felt, and then thermally treating the material to cause the binder fibers to adhere to other fibers in the felt matrix, imparting strength. In this case, the more open structure will have benefits such as reduced cost due to less fiber per unit volume, as well as reduced pressure drop in filtration applications.
  • a carded needled felt is manufactured from a blend of commercial Profilen® PTFE staple fibers and 5 denier, 3.5" long crimped staple fibers made from Hyflon® melt processable perfluoropolymer with a melting point of approximately 290° C.
  • the felt contains a ratio of 80% by weight Profilen® PTFE fibers and 20% by weight of melt processable perfluoropolymer fibers randomly mixed. Carding and needling conditions are adjusted to give a weight of approximately 20 ounces per square yard.
  • the use of humidifiers and ion generators are used to reduce static during the felting process.
  • a piece of felt is then placed in a hot air circulating oven and heated to 300° C for approximately 2 minutes (until the web temperature is nearly uniform).
  • the article is then placed in a molding machine with vacuum applied to one half of the mold and the other half pressed against the first half using pressure.
  • the pre-heated felt is held in place between the two mold halves and cooled below 200° C. Once the felt is cooled, the mold is opened. Inspection of the felt shows that the melt processable perfluoropolymer fiber has melted and bound with the Profilen® PTFE fibers, and taken on the shape of the mold cavity.
  • the product is resilient and resistant to compressive set.
  • a carded needled felt is manufactured from a blend of homofilament staple fibers made from two different melting point melt processable perfluoropolymers. Both types of melt processable perfluoropolymer staple fibers are produced from Hyflon® perfluoropolymer. Individual fibers for both are approximately 2.5 denier, 3.5" long, crimped, and have a tri-lobal cross section. Approximately 20% by weight of the fibers are made from a Hyflon polymer with a melting point between 265 and 290° C, and the other 80%) of the fibers is made from a Hyflon polymer with a melting point between 290 and 320° C. The fibers made from the lower melting polymer are unoriented (UOY).
  • the fibers are randomly mixed. Carding and needling conditions are the same as in example 1.
  • a piece of felt is then placed in a hot air circulating oven and heated between 280 and 300° C for approximately 2 minutes (until the web temperature is nearly uniform).
  • the article is then placed in a molding machine with vacuum applied to one half of the mold and the other half pressed against the first half using pressure.
  • the pre-heated felt is held in place between the two mold halves and cooled below 200° C. Once the felt is cooled, the mold is opened. Inspection of the felt shows that the low melting melt processable perfluoropolymer fiber is melted and bound with the high melting perfluoropolymer fibers, and taken on the shape of the mold cavity.
  • the product is resilient and resistant to compressive set.
  • a 100%) perfluoropolymer Web is produced as in Example 2 except that a 110 gram/meter squared weft insertion woven scrim was placed in the middle of the parallel-layered webs. Carding and needling procedures typically used to process other synthetic fibers, such as polyester and polypropylene, were used. Like the nonwoven felts described in examples 1 and 2, the resulting felt can be shaped by the use of pressure and/or vacuum and elevated temperature.
  • the needled felt of Example 3 is densified using a heated calendaring operation.
  • the felt is continuously pre-heated and pressed between a set of nip rolls, at a temperature of 280 to 300° C, yielding fabric with higher density, decreased air permeability, reduced pore size, and with fiber to fiber adhesion.
  • Fabric gauge is controlled by varying the gap between nip rolls, with minimal expansion after calendaring. Nip roll gap is adjusted to obtain a fabric density (target) of 0.275 ounces/inches cubed.
  • a blend of 40% 5.5 denier MFA fibers, 40% 6.7 denier PTFE fibers, and 20%) 0.3 denier E-glass fibers are blended and processed on a Rando-Webber air- laying device.
  • the fibers are first cut to the appropriate length for use in this type of apparatus. Good quality webs are formed. The resulting web can then be subjected to a calendaring process, or molded, using temperatures of 280 to 300° to make a fabric article with fiber to fiber adhesion, crush resistance, improved dimensional stability, and improved resiliency.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

On peut améliorer des tissus et toiles à hautes performances par incorporation de fibres et/ou filaments de perfluoropolymères traitables à chaud. Lorsqu'on les chauffe au-dessus du point le plus bas ouvrable à l'état fondu du perfluoropolymère constitutif d'un tissus ou d'une toile, mais au-dessous du point de fusion ou de décomposition des autres fibres ou filaments présents, les fibres et/ou filaments de perfluoropolymères traitables à chaud fondront et adhéreront aux autres fibres et constitueront des éléments de liaison; de par leur nature de perfluoropolymère, ils présentent une excellente résistance aux produits chimiques, sont utilisables à température élevée, sont peu inflammables et peu combustibles, et ont d'excellentes propriétés à basse température, ce qui contribue à les retenir comme éléments de liaison même dans des conditions sévères d'utilisation. Les avantages de cette adhésion fibre à fibre comprennent: la capacité de mouler ou mettre en forme le tissu ou la toile qui gardent leur forme, une stabilité dimensionnelle renforcée, une résistance aux déformations telles que celles dues aux chutes de pression, à la gravité et aux contraintes mécanique prolongées, plus de gonflant, et une structure plus ouverte permettant des allégements de poids non préjudiciables à la résistance, une bonne tenue à la compression, et un toucher plus doux et plus moelleux. L'utilisation de fibres de liaison de perfluoropolymère est particulièrement utile dans des tissus ou toiles contenant 100 % de fibres et filaments de perfluoropolymère tels que ceux de polytétrafluoroéthylène et/ou autres perfluoropolymères à point de fusion élevé, et traitables à l'état fondu.
PCT/US2002/031255 2001-10-02 2002-09-30 Formes moulables a haute performances non tissees, tissees ou tricotees WO2003029541A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007066240A3 (fr) * 2005-01-10 2008-01-24 Smiths Detection Inc Ecouvillon d'echantillonnage
GB2441589A (en) * 2006-09-05 2008-03-12 Anthony Walter Anson Heat treatment method for composite textiles
WO2013078049A3 (fr) * 2011-11-22 2015-05-21 Easton Sports, Inc. Instrument de sport formé avec un liant structurel pouvant être traité à l'état fondu

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020155289A1 (en) * 2000-09-01 2002-10-24 Frank Cistone Melt processable perfluoropolymer forms

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020155289A1 (en) * 2000-09-01 2002-10-24 Frank Cistone Melt processable perfluoropolymer forms

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007066240A3 (fr) * 2005-01-10 2008-01-24 Smiths Detection Inc Ecouvillon d'echantillonnage
US9200992B2 (en) 2005-01-10 2015-12-01 Smiths Detection Sampling swab
GB2441589A (en) * 2006-09-05 2008-03-12 Anthony Walter Anson Heat treatment method for composite textiles
WO2013078049A3 (fr) * 2011-11-22 2015-05-21 Easton Sports, Inc. Instrument de sport formé avec un liant structurel pouvant être traité à l'état fondu

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