WO2016003261A1

WO2016003261A1 - Method for non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties

Info

Publication number: WO2016003261A1
Application number: PCT/MX2015/000098
Authority: WO
Inventors: Mario OROZCO OBREGON
Original assignee: Orozco Obregon Mario
Priority date: 2014-07-04
Filing date: 2015-06-26
Publication date: 2016-01-07
Also published as: MX369712B; MX2014008277A; US20160160412A1

Abstract

The invention relates to a method for obtaining non-woven fabrics with acoustic, thermal and filtering properties, said fabrics being obtained using a mechanical method of carding or hydroforming and strengthened by hydroentangling or needlepunching, being optionally reinforced with a polymer resin. The method is characterised by the use of a novel mixture of fibres of different deniers between 0.01 and 30, inclusive, as well as fibres that can be of synthetic, natural and/or mineral origin, for acoustic, thermal, filtering, comfort and cleaning uses in various markets.

Description

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The present invention relates to a process for manufacturing nonwoven fabrics and their products with acoustic, thermal, filtering, comfort and implexability properties obtained by means of fiber masses, of various designs, different denier and similar or different chemical nature, attached by hydrollgado or ponzoñado with good properties for applications as acoustic, thermal insulating and with filtering and comfort applications for various industries such as footwear, construction, automotive, filtration, clothing and cleaning.

OBJECTIVE M THE «VENC ÓN

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The objective of this invention is to produce non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties with a novel technique, being lighter or at least of the same weight, but more efficient in said properties, as shown below.

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Several processes have been used for the consolidation of a non-woven fabric, for example it can be done by punching, hydrolling or chemically bonded, the document US401S646 deals with consolidations in addition to cardings, pressed through two rollers, thus changing its surface design, giving the appearance of greater compaction. There are also examples MX1929629, of our authorship, which deals with devices that favor water pressure and thus the attachment or consolidation with high pressure water jets, "droll" This invention achieves innovative properties Innovating over previous arts. Including our patent MX28228S, where fabrics or woven fabrics are obtained by mixing long fibers of 100 mm long to continuous filaments and short hours of ϊ mm, 100 mm is sufficient by wet or dry route and consolidated by a process of pumonado, hydrolyzed, thermolyzed or chemically bonded or a combination of porous nonwoven fabric with a also porous woven fabric.

Now, this invention presents innovation by interacting with fiber blends ranging from 0.01 denier to 30 denier, designing structures for the formation of cavities that favor acoustic and thermal properties, as well as the generation of pores for correct ta Separation of materials that can be filtered in these nonwoven fabrics, there are also properties of comfort and retention of particles that are used in the cleaning market, this is achieved with rnexelas of different denier and different lengths.

The present invention is the result of intensive research and development, designing properties that can be applied to achieve functionality with the same or less weight, translating this to lighter constructions, silent and thermally insulated spaces, lighter, faster and quieter cars for ® the driver, more efficient filtration and deeper cleaning with lighter products, this achieved with a non-woven fabric obtained with a mixture of fibers of different denier from 0.01 to 30, ensuring or not the extension of properties with the support of a Polymeric resin to obtain a final weight of between 0 to 2000 g / m ² .

The present invention relates to a non-woven fabric made of fibers obtained with polymers of different chemical nature such as polyester, polyolefins, aoliamides, lactic polyfacsdo), acrylics, polyamides, cellulosics, cotton, rayon, glass phosphorus, low melting polymers or combination of these maintaining the differential of denier from 0.01 to 30 and ensuring not the extension of properties with the support of a polymeric resin to obtain a final weight between 40 to 2000 gm ² .

It is observed that the products resulting from this invention have the advantage that with the same weight and thickness conditions we can obtain superior acoustic, thermal, filtration, anchoring and comfort properties, thus allowing the weight reduction, this due to the appropriate integration of components by means of denier and correct fiber nature to obtain a product with better performance, according to the market requirement.

In the acoustic properties for these materials a high absorption coefficient is required, which indicates the level of sound absorption of the materials * but especially for compact materials the high transmission loss is used, which shows the sound levels that are they lose to the muúir on the materials, another acóstlca property that is improved with this novel nonwoven fabric.

As for the thermal properties, the nonwoven fabrics products of this invention have a lower thermal conductivity to conventional nonwoven fabrics, due to their design since their construction allows a novel structure and distribution of empty spaces and for this reason combine * the thermal conductivities of air and fibers that contribute to the overall conductivity coefficient

The filtering properties are achieved in the sense of containing cavities that allow to increase the capacity and narrow channels that retain smaller particles and therefore improves the efficiency of the nonwoven fabric described herein.

§¾0Sif MA TtalCO TO BE RESOLVED This invention relates to the process of nonwoven fabrics and nonwoven fabrics themselves with acoustic, thermal, filtering, comfort and cleaning properties with better performance and efficiency than traditional nonwoven fabrics in the same conditions , in addition to providing u easy handling unlike fabrics made specifically to attack each property, that is, they do not cause them to give them or risks to the human being to the environment, in its management and functionality.

BRIEF DESCRIPTION OF THE FDIURES Figure i shows a cross-section of the nonwoven fabric with acoustic, thermal and filtering properties, in accordance with the present invention. Figure 2 shows a cross-section of the non-woven fabric of Figure 1, with a variation of the invention, a polymeric resin application to increase the performance, favoring ø expanding the properties of the final product.

Figure 3 shows the comparative acoustic graph of a traditional nonwoven fabric with two examples of nonwoven fabrics obtained in accordance with the present invention.

Figure 4 shows a comparative graph in the filtration efficiency properties, where the non-woven theias of Figure 3 are compared. DET & tL & DA DESCRIPTION OF THE INVENTION the characteristic details of this novel method of obtaining non-woven theias with acoustic, thermal properties , filters, comfort and cleanliness are clearly shown in the following description and in the accompanying eyes.

The procedure for preparing a non-woven fabric with acoustic, thermal filter, comfort and cleaning properties according to the present invention consists in: a) Making a non-woven fabric by commenting with the mixture of fibers of different denier, that is to say with a diameter differential wide, where the length of the fibers can be the same or different from each other, with a mechanical method of carding or hydroforming or formed with air,

b) Once the veil has been formed in accordance with part a), it is consolidated by any of the hydrophobic, punctured, thermal, sewn, chemical and combination of these, if the process is hydrogenated, it is designed using hydraulic pressures from 20 to 400 bars. favor the mooring between fibers that have wide denier differential; if the process is punctured, mooring is allowed with a design with the optimum densification of nonwoven fabrics.

c) Once the fabric is formed, a variation is possible by adding a heat treatment by contact with a hot surface or hot air oven, making the nonwoven fabric increase its dimensional stability, this treatment will vary depending on the nature of the fibers, that is, it can be carried out from BOX to u) Another variation of the final process involves the incorporation of a polymeric resin, first a suspension of the selected polymeric resin is prepared according to the properties, such as tensile strength , rigidity, touch, surface tension, visual appearance, object of this invention, where the suspended polymer particles are incorporated into the nonwoven fabric when together they pass through a pair of rollers, forcing the nonwoven fabric to saturate. Then, it is dried and finally an additional thermofused material is imparted so that the polymer added to the nonwoven fabric acquires greater tensile strength,

As the term nonwoven fabric is used, it generally includes, but is not limited to nonwoven fabric made of synthetic, natural, mineral and / or thermo-plastic fibers, made of polymers such as polyester, chickenlefins, polypropylene, polyamides, lactic polycloth) , aerificas, polyamide, cellulosic, cotton, rayon, fiberglass and low melting point polymers and combinations thereof. In the non-woven fabrics mentioned, short fibers are mixed with different denier that can be from mieroflbras of 0.01 denier to 30 denier and with different lengths of 3 mm, just 1S0 fflffl or continuous filaments or combinations thereof. The fibers may also have differences in their transverse geometry, which may be circular, symmetrical or irregular, solid or with internal spaces or a combination thereof. These nonwoven fabrics are manufactured by any of the known methods, such as pneumatic, wet and mechanical formation, consolidating this formation with methods such as hydrollgado, punching, thermal, sewing, chemical and combination of these processes.

It should be mentioned that fibers of the same nature or chemical composition, or different, can be used in the same fabric, favoring, according to the case, the greater denier differential or the proportion suitable for the specific application.

In this invention, the term "polymer resin" includes, but is not limited to, airborne, polyurethane, latex, stretch-acrylic, phenolic, vinyl, non-toxic and combinations of these resins, in addition to chlorofluorocarbons, surfactants and organic and inorganic phosphates and combinations between are you, using any of the - δ - known methods; Impregnation with resins with different densities or mixture of these, are applied directly after forming the nonwoven fabric obtained by ligation or stabbing to favor or achieve important properties object of this invention,

Nonwoven fabrics can have final weights of 40 gm ² up to 2QQ0 g / m ² .

As the term differential of denler is used, where the term "denier" is defined as the weight in grams of a continuous filament of 9000 meters of the same diameter, therefore that of ier is a relation of diameter and the density of the material with that the fiber is obtained, thus the denfer differential refers to the fact that thin fibers from 0.01 denter and thick fibers can be used on the same fabric enough SO deruer, this combined with the properties of the materials with which they are obtained the fibers, create structures and design of spaces to fragment the sound waves and have high sound absorption; These spaces can also be designed to favor the separation of micrometric particles from an air flow, individually or in combination with the processes to obtain products with filtration properties. Also the combination of air inside these cavities and the material with which the fibers are made become two parallel resistors that achieves the thermal insulation of the nonwoven fabrics product of this invention.

Referring to the drawings in particular in Figure 1, a cross-section of the non-woven fabric with acoustic, thermal and filtering properties is observed where an example of the design of the different diameters of the fibers used, where (a) are the fibers Thin and (b) are the thick fibers, which according to the arrangement of said fibers in the nonwoven fabric generate * cavities that vary with the differential of the selected diameters.

In another embodiment of this invention illustrated in Figure 2, we have the cross section where (a) are the fine fibers, | b) are the thick fibers and faith) are the moorings reinforced with polymeric resin.

In Figure 3 an acoustic graph known as Absorption Coefficient ^* is schematized, where the frequency is in Herte, in the axis of the abscissa, a fraction where the audible spectrum (20 za 20 kHz) and where the human ear has greater sensitivity f 2 kHi at 4 kHz), thus the graph goes from O to 5000 Hz and the absorption coefficient of the materials ranging from 0 to 1 is shown on the ordinate axis, from "O ^* the material does not Absorb any sound and "1 * the material absorbs all the sound. In this graph, three materials are compared where {1} is a non-woven bi-woven fabric, with a single type of 3 denier polyester fiber, (11) it is a hydrolyzed nonwoven fabric with a mixture of 15 denier polyester fibers and polyester 0.01 denier and {ΠΙ1 is a non-woven hydrophilic fabric with a mixture of 7 denier polyester fibers, 13 denier polyolefin and 0.01 denier polyester, where {II} and {111} are in accordance with the present invention, All three fabrics are manufactured at $ 200 and under the same process conditions.

Thus in the graph of figure 3, you can see how the denier differential that is presented in this novel art favors sound absorption,

the thermal properties are favored with the same denier differential present in the fabrics of figure 3, while qu ÍJ | The non-woven fabric with similar Denier fibers m polyester) has a thermal conductivity of 0.29 / mYes (Watts per meter and Kelvin grade), the non-woven fabric (ÍIJ has a thermal conductivity of 0.24 W / mK and the non-woven fabric with the greatest denier differential {111} reports a thermal conductivity of 0.19 W / mK, thus the fabric with the highest differential provides greater resistance to the heat flux with the same thickness as the other fabrics, since at lower conductivity thermal resistance to heat flow with the same thickness.

As far as filtering properties are concerned, we have that the nonwoven fabric (!) With a single type of 3 denier polyester has an average pore diameter of 45 pm, and the nonwoven fabric {11} with fiber blend of Polyester of 1.5 denier and polyester of 0.01 denier, yields an average pore diameter of 26 prn, finally to non-woven fabric with greater denier differential (III) with a mixture of 7 denier polyester fibers, polyolefsna 1.5 denier and 0.01 denier polyester reports an average pore diameter of 32 μηι, which favors these filtering properties, since at a smaller diameter on average the teat or fabric is selective with the smaller diameter particles and the size of the design is designed. pore depending on the particles to be filtered. This is clearly seen in the graph d Figure 4 d "Filtration efficiency", where the efficiencies are compared * s »

in filtration, that is, the small pore behaves better with the smaller particles, as well as the uptake of pol that are favored by the novel conditions of the present invention, since the non-woven fabric (I) has an uptake 120 g¡m2, while the non-woven fabric (Π) has a collection of 215 g m2 and the non-woven fabric {II!} has a collection of 240 g / m2 _f and in the efficiency property the non-woven fabric {ϊϊΐ) has a particle retention between 0.3 and 0.4

Considering that what has been said above broadly describes the method of obtaining by means of fiber masses, as well as the figures, some examples of its application are given below.

To make a non-woven fabric with acoustic, thermal, ortho and cleaning properties, they are first mixed and formed 1.5 d polyester fines

long and polyester fibers 0,01 dewer by 51 mm long, with mec ^" carding oil.

Once the veil is formed, it is consolidated by a hydraulic hydration process from greater to lesser to favor the mooring between jras that has ^a large denier differential.

Finally, the woven fabric is dried in a process of hot air contact on hot surfaces.

In this example, the additional resin reinforcement section was used so that when obtaining the non-woven fabric, a water-based solution is applied that carries ¾ acrfllcas particles and is dosed in a pair of rollers, forcing the solution * ¾r l fabric no woven, then dried and finally imparted a thermofundid, 1, so that the nonwoven fabric acquires greater tensile strength.

Thus the 200 gm ² fabric has the following relationship:

1} I denier fibers on average by 51 mm long

2! Acrylic resin The acoustic properties of this exemplary embodiment 1 are expressed in the non-woven fabric | ΐΙ) of Figure 3.

EXAMPLE OF EMBODIMENT 2.

In this exemplary embodiment of a hydrolyzed nonwoven fabric with acoustic, thermal, filtering, comfort and cleaning properties, 7 denier polyester fibers are mixed by 51 mm long, 1.5 denier polyolefin fibers and 0.01 polyester fibers denier by 51 mm long, with a conventional mechanical carding method.

Once formed e! Veil is consolidated by a conventional hydrolyzate process with hydraulic pressures from high to low to favor the mooring between fibers that have large denier differential.

Finally, the nonwoven fabric is dried with hot air or by contact on hot surfaces and finally an additional heat treatment is imparted so that the nonwoven fabric acquires greater tensile strength.

Thus the 200 g / m ² fabric has the following relationship:

1) 2.5 denier fiber on average .... 100%.

The acoustic properties of this example of embodiment 2 are expressed in the non-woven fabric (III) of Figure 3, where the best acoustic properties are observed thanks to the denier differential and nature of the fibers.

Claims

mmumchc ms Having described the invention as above, the following is claimed as property:

1.- Procedure for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, characterized in that it comprises the steps of: a) Manufacture of a non-woven fabric with a mixture of fibers with a wide denier differential by any of these methods such as: pneumatic formation, wet or mechanical way, consolidating this formation with processes such as hydrofoil, ponzo ado, thermal, sewn, chemical or combination of these,

b) Apply heat to the product derived from the process a) Wet or hydrolyzed route to dry in a process by hot air or by contact with hot surfaces between 100 and 240T and provide additional heat treatment if necessary between S0T and 250 ^* C to the product derived from process a),

c) Incorporate a polymeric resin, as optional variation after the process a) and b), preparing a water-based polymorphic resin suspension to favor the properties of resistance, stiffness, stability, forming, sound absorption, surface tension, filtration capture efficiency and thermal resistance where polymer suspended particles are incorporated into the nonwoven fabric when together they pass through a pair of rollers- di The nonwoven fabric impregnated with polymeric resin obtained in the process c) is dried by hot air or by contact with surfaces between 100 and 240X, providing a heat treatment, between 100 and 250T, for an additional thermo-ligation so that the polymer added to the woven fabric acquires stability and finishes developing the properties described in process c),

e) In an additional variation to the processes a) and b) with the presence of low melting point fibers, a heat treatment between 100 and 20GT is applied to activate these fibers γ, thus achieving thermoligating, imparting dimensional stability, durability and consolidating the structure .

2 ~ Procedure for obtaining nonwoven fabrics with acoustic, thermal, mitigating, comfort and cleaning properties according to claim i, characterized in that the fiber mixture comprises dersier differential of between 0.01 denier and 30 of them as well as its transverse geometry can be circular, symmetric or irregular, solid or with internal spaces or combination of these.

3. ~ Procedure for obtaining nonwoven fabrics with acoustic, thermal, filtering, comfort and cleaning properties according to claim 1, characterized in that the fiber blend incorporates short fibers that include from 3 mm to 150 mm long and up to filaments continuous,

0 4. ~ Process for nonwovens acoustic, thermal, filter, comfort properties and cleanliness according to claim l _s wherein the combination of fibers falls within the group of conventional synthetic fibers, natural fibers, minerals and thermoplastics, such as polyester, polypropylene, polypropylene, polyamide, poly {lactic acid), aerificas, cock dull, cellulosic, cotton, 5 rayon, fiberglass and low melting fibers (11GT to 200 * C), and these polymers are comprised in homopolymers or combinations thereof,

5. - Procedure for obtaining nonwoven fabrics with acoustic, thermal, filtering, comfort and cleaning properties in accordance with claim I, characterized in that the fiber mixture considers combinations of denier, length, 0 geometry and group of fibers according to their origin. , the latter also according to claim 2, 3 and 4.

. - Procedure for obtaining nonwoven fabrics with acoustic, thermal, filtering, comfort and cleaning properties according to claim 1, subparagraph c), characterized in that the polymeric resin is within! group that include acrylic, polyurethane, latex, styrene-aerobic, phenolic, vinyl or epoxy resins, as well as chlorofiuorocarbons, surfactants and organic & inorganic phosphates and combinations between these »

7. ~ Procedure for obtaining nonwoven fabrics with acoustic, thermal, filtering, comfort and cleaning properties d # in accordance with claim 1, characterized in that the weight of the nonwoven fabric obtained in accordance with fas claims ia 8 is in the range ele 40 to 2000 g / m \

8 <- Nonwoven fabrics, products, derivatives and their applications, obtained by the process in accordance with claims 1, with acóstic properties¾. thermal, filtering, comfort and cleaning as resistance, stiffness, stability, forming, acoustic absorption, surface tension, efficiency and capture in filtration and thermal resistance, for industry markets such as footwear, construction, automotive, filtration, clothing and cleaning.