DE1055939B - Composite of soft, highly flexible fiber outer layers and a reinforcing intermediate layer - Google Patents

Description

GERMAN

kl. 55 f 8

INTERNAT. KL. D 21 Il

PATENT OFFICE

110397 VII / 55 f

REGISTRATION DATE: JULY 7, 1955

NOTICE
THE REGISTRATION
AND ISSUE OF THE
EDITORIAL: APRIL 23RIL 1 9 5 9

Composites made from soft, highly flexible fiber outer layers, like crepe paper, and a reinforcing liner made of spaced apart extending flexible threads that are glued to the fiber layers are known. With the well-known Execution is a particularly tear- and moisture-proof material, which is particularly suitable for Packaging purposes is intended. The reinforcing threads consist of cotton, jute, hemp, Sisal or similar yarns.

In contrast, the invention is essentially to be seen in the fact that the reinforcing Threads made from highly flexible monofilament, endless fibers twisted together with a weak twist are. The purpose of this measure is to keep the composite material despite the reinforcement layer particularly soft and supple, so that it can be used as a textile substitute for the manufacture of towels, Wipes, aprons and the like can be used, what with the mentioned, known Material is not intended.

There are also textile substitutes in the form of towels, handkerchiefs, tablecloths, Napkins od. Like. Already known, the outer layers of z. B. from creped or uncreped cellulose wadding exist and the reinforcing liners z. B. made of interwoven threads or cotton wool, meanwhile cotton or similar fabrics or even cotton wadding or the like can also be used for comparatively with the same tear strength do not provide such a soft and pliable product as can be achieved by means of the according to the invention used reinforcement intermediate layer is possible.

The composite according to the invention has, despite the processing of loose and weak substances, for would not be able to withstand the stresses of normal use alone, sufficient strength and due to its great softness and suppleness it can be folded and creased without to lose its usefulness; it is not on par with reinforced cloths of this kind in terms of softness and suppleness not after and is relatively cheap to manufacture.

Further features of the invention emerge from the subclaims, some of the characteristics of which are attached known, but in the combination according to the invention are new and advantageous embodiments of the Have the subject matter of the main claim.

The figures show exemplary embodiments of the substance according to the invention and devices for production same. It shows:

1 shows the plan of a cellulose wadding on an enlarged scale,

Fig. 2, also on an enlarged scale, a composite material made of soft,

highly flexible fiber outer layers

and a reinforcing liner

Applicant:

Kimberly-Clark Corporation,
Neenah, Winnebago, Wis. (V. St. A.)

Representative: Dipl.-Ing. F. Weickmann

and Dr.-Ing. A. Weickmann, patent attorneys,

Munich 2, Brunnstr. 8/9

Claimed priority:
V. St. v. America September 30, 1954

Kenneth John Harwood, Neenah, Winnebago,

Wis. (V. St. A.),
has been named as the inventor

Thread network to reinforce the fabric shown in Fig. 1,

Fig. 3 shows the section along line 3-3 to Fig. 2,

4 shows the section along line 4-4 to FIG. 1, the fabric thickness being drawn exaggerated to scale,

FIGS. 5 and 5 a two further exemplary embodiments of the invention,

Figures 6, 7 and 8 show different methods of manufacture of the fabric shown in Figs.

The composite according to FIG. 1 consists of four layers 1, 2, 3 and 4 of creped paper or cellulose wadding. These layers are preferably very thin and porous, although if desired they can also be used in larger layer thicknesses. Advantageously, however, the layers are so light and so thin that they cannot be used without a supporting or reinforcing thread network. Between the inner layers 2 and 3 there is a reinforcing and binding net 5, which consists of longitudinal and transverse threads. The net can be braided or consist of two non-interwoven, superposed layers of intersecting threads in such a way that the position of one thread is entirely on one side of the position of the other threads. These thread layers are preferably glued to one another at the crossing points, but this is not necessary.

909 507/501

3 4

The threads can run parallel, but the network consisting of crossing threads is also

this is not essential; they can be stretched or as shown in FIG. 2 by any suitable means

be laid in a wave shape in such a way that the threads of the thread laying device are generated; an execution

every position in a main direction, but not necessarily an example of such a device known per se, is in

agile parallel to each other. On the threads 5 Fig. 6 is shown. A number of threads 6 is over one

of the thread network applied adhesive binds the adhesive application roller 12, which is in one with

Cotton layers 1 to 4 to one unit. The adhesive adhesive-filled trough 13 rotates. The strings

need not, however, be carried by the thread net 5 to accept an adhesive coating from the roll 12

to be; He may be in a suitable distribution or and be spaced over one another

Patterning on one of the inner layers 2 or 3 in io elongated, cylindrical mandrel 14 by means of a

a guide device 15 ensuring the required binding. Depending on the type of

Applied amount or on the outside of the fabric-turned adhesive, this can be applied to the threads.

formed be printed so that it dries the wadding or partially dried to a

penetrates and these with each other as well as sticking to the guide device 15 or the

Reinforcement mesh binds. The adhesive can prevent the pin 14 from closing. By appropriate treatment,

borrowed both the threads of the thread network and z. B. with heat or moisture, the adhesive becomes

be applied to the cotton wool layers. reactivated at the appropriate time so that the threads

An embodiment of the network 5 shows one another and with the other components of the

enlarged scale Fig. 2, according to which the fabric stick together.

Network of longitudinal threads 6 and transverse threads 7 consists. 20 On a rotatably mounted and driven The threads are made of endless monofilament individual fibers ring 17, one or more thread spools 16 are put together and arranged with a slight twist, so that the thread spools 16 twisted around the mandrel, so that each thread is very flexible and circle while one or more threads 7 are soft. The threads preferably consist of the longitudinal threads, which are soft rayon or similar fibers along the dome. The 25 promoted will be wrapped. The adhesive carried along by the flexibility and softness of these threads is such that the longitudinal threads 6 are used to bond the transverse threads 7 to the first-mentioned shape, they quickly become somewhat flattened or threads. The tubular network thus produced assume an oval cross-sectional shape, as at 8 in FIG. 3, is cut open at 18 and shown at 19 in the plane. This flattening results in the passage 30 unfolded. The tension under which the transverse of the thread under slight tension through or over threads 7 are wound around the longitudinal threads and the mandrel guide elements during the final stages of the thread, is sufficient to produce the above-mentioned flattening, and also to bring about the intersections by winding the threads . The thread structure on bobbins or reels. If the thread layers, as shown in FIG. 19, can run between conveyor rollers, which are shown in FIG to flatten at the crossing points as the threads press tightly together and shown at 9 in FIGS. This flattening will flatten intersections. This also increases the effects of stresses on the thread structure, mutual embedding of threads 6 and 7 and mutual gluing such as brushing or calendering or similar handling. For certain lungs, being subjected. As shown in Fig. 3, for purposes of this, the calender can be heated.
the thread 7 at the intersection with the thread 6 in The adhesive application roller 12 can be designed in such a way that the adhesive coating on the threads 6 is flattened; likewise the thread 6 becomes continuous in one area, as indicated in FIG. 2 at the points marked with 21 bell, the one in the flattened area 10 of the other, 45. For example, the crossing thread may lie. As already mentioned, the application roll with openings or recesses results in the flattening alone when looking at one another, in the area of which an application of adhesive is applied to the two layers of thread; but it is severely disrupted by the threads; However, the roll can also be enlarged by calendering, which either have a smooth surface and run at a peripheral final stage in the generation of the network or speed that is slightly smaller than the final stage in the generation of the multi-layer conveying speed of the threads, so that in the final product according to Fig. 1 or in both stages the roll 12 is made through the threads on the glue of its manufacture. A stretching effect is exerted on the fabric cover.

This stretching, which consists of a multitude of fibers, causes the Threads 6 and 7 have a denier on the order of 55 adhesive coating and are produced in an irregular order from about 30 to 150, each two moderate distances encompass the adhesive bis already mentioned one hundred and fifty continuous fibers and have a vacancy 21. The number of glue-free spots Twist less than 6 per 2.5 cm. (1 denier can be widely regulated by promises a weight in grams of 9000 m of yarn change in the ratio between the conveyor or Thread; in other words, 50 denier means 60 thread speed and circumferential speed 9000 m of thread weighs 50 g.) The individual fibers are dense on the adhesive application roll. The glue-free in the threads have a denier value equal to the size- points are used to maintain normal softness Order from about 1 to 15. With a practical and flexibility of the longitudinal threads; i.e., they decrease Embodiment, the transverse threads 7 100 denier have the stiffening effect of the adhesive on a and consist of forty individual fibers with a twist 65 minimum. The transverse threads 7 are nevertheless on all of about 4 per 2.5 cm. The longitudinal threads have high longitudinal threads bound by glue, out-75 Denier and consist of thirty individual fibers where one of the irregular ones happened to occur Twist around 2V2 per 2.5 cm. You use the glue-free areas you see on a thread spool spun threads with a low twist to meet the tongue. There will therefore be an effective binding of the to obtain desired softness. 70 transverse threads reached with the longitudinal threads, even if

at a few intersections no sticking occurs.

A device as shown schematically in FIG. 1 serves to combine the elements 1 to 5 shown in FIG Fig. 7 is shown. This consists of a conveyor belt 22, on which the elements 1 to 5 continuously are stacked, with the deduction of supply rollers. The conveyor belt 22 gives the united Elements on guide rollers of a calender 23, which generates the desired, controllable pressure. After the calender, the combined fabric product is wound up or subjected to an additional treatment subject.

When calendering the finished product or the thread structure 5 before it is combined with the Wadding layers 1 to 4 flattening occurs at the intersections to such an extent that the sum the strengths of the crossing threads is reduced to a level which is a little larger than normal Diameter of a single thread. You can even choose the calender pressure so large that the Strength in the crossings η iaht noticeably different is on the thread size between the crossings. To cut the threads at the crossing points To prevent under the action of the pressure exerted, one of the calender rolls can, between which the structure runs through are made of cotton, the other of steel. The proportionate soft cotton roll is sufficiently elastic to allow the fabric to be calendered partially into the roll to prevent the threads from being cut. The longitudinal threads of the thread structure sioh are preferably located on the side that rests against the cotton roller, so that these threads as a means act to pull the transverse threads off the cotton roller. If the glue on the threads is sensitive to heat is, the flattening produced by the calender can be increased if the Calender heats.

The glue used to bind the threads together is such that it will be used for the final product desired properties, e.g. B. with regard to flexibility, water resistance, oil resistance, binding force etc. owns. An example of the adhesive is a polyvinyl acetate solution that contains a plasticizer. Such an adhesive contains e.g. 30% polyvinyl acetate, 67% solvent and 3% dibutyl phthalate plasticizer. Comes as a solvent z. B. contemplated one containing about 90% ethanol and about 5 weight percent ethyl acetate. This adhesive has the property of remaining flexible and not penetrating into the threads, but rather predominantly to adhere to the surface, whereby a stiffening of the threads is avoided and a effective introduction of the transverse threads into the adhesive coating is guaranteed. Also this is glue thermoplastic. Adhesives in the form of emulsions can also be used, as well heat fusible adhesives such as polyethylene. In general the adhesives are of medium grade to a high viscosity, so that they have a tendency to stay on the surface of the thread and to expand not along the surface of other threads that come into contact with it.

In the illustrated exemplary embodiments, the adhesive to be applied to the longitudinal threads 5 is used is, preferably thermoplastic adhesive used, so that when the product is in a hot calender is treated, a reactivation of the adhesive occurs, which then spreads over the flattened, widened Stretches crossing points and thereby ensures a particularly good bond. Through the Reaktivi'crung is also achieved that the adhesive penetrates into the adjacent layers of cotton wool 2 and 3 and thus also causes the outer layers 1 and 4 to bond.

A particularly durable product is preferred for towels, and this is supported by the described Execution created, d. H. through the adhesive

ίο Binding of the individual components along the relatively narrow zones in the area of the threads provided with adhesive 6. In a practical embodiment, the network has a mesh size of 4-4, so that only a very small percentage of the total area is adhesive-bonded, namely the places in the Areas of the adhesive-bearing longitudinal threads 6. (Mesh size 4-4 means that there are four threads per 2.5 cm in each direction.) The areas in between remain free of adhesive and become soft or fluffy depending on the moisture content of the material calendered, fluffy structure, as indicated at 24 in FIG. 1. The downy texture is apparently due to a slight shrinkage of parts of the wad layers along the threads 6 and 7, especially along the threads 6 coated with adhesive, or to a consolidation of the wad layers along these threads during calendering, the surface areas 24 stay in a relatively uncompact condition.

According to an exemplary embodiment, a calendered Layer the thickness of about 0.16 mm.

If desired, the wadding layers 1, 2, 3 and 4 can be made moisture-proof by suitable treatment, but usually at the expense of absorbency. Mostly and especially for towels, however, a high absorbency is desired, for which reason the treatment to achieve wet strength, if used at all, is reduced to a minimum. The thread structure embedded in the layers gives the end product a high tensile strength in all directions so that, even when moistened, it does not tear under normal conditions of use and can be folded and creased as desired.

Towel fabric made in the manner described is still soft and flexible and feels like an ordinary towel fabric. He sees also due to the pattern given by the presence of the reinforcing thread structure. The threads are not visible on the outside of the composite material, but are noticeable, as at 25 indicated by thin lines after calendering.

Calendering also has the effect that the flattened filaments are barely perceptible, if at all are. The disappearance of the threads is particularly evident when they are soft and only slightly twisted Uses small denier threads and subjects the threads to a treatment whereby the Outer layers are puffed up more or less fluffy. The softness of such a calendered structure results in a surface that can be easily printed.

The fleece character, the softness and adaptability of the composite are multiplied, if the layers, as indicated in FIGS. 1 and 4 at 26, are creped or puckered. The creping occurs irregularly, i.e. not continuously in

one direction across the width, but discontinuous. For example, the composite is after after leaving the calender 23 (Fig. 7) moistened at 27 (e.g. sprayed with finely divided water), over a rotating roller 28 which is used to dry of the fabric can be heated, and guided by this under creping or fluting with the help of a scraper 29 deducted. The creped or corrugated fabric 26 is delivered to a conveyor belt 30 and thereafter fed to a take-up roller or other device.

The creping reduces the uniform fleece pattern of the fabric indicated at 24 in FIG. 1 and gives it the appearance of a linen fabric. On the other hand, the creping or corrugation increases the absorption capacity per unit area, which is particularly advantageous when used as a towel.

Another embodiment of towel fabric is shown in Figure 5; this fabric consists of layers 31 and 32 of carded fiber webs; each layer has a weight on the order of about 4 to 7 grams per 0.914-0.914 m; in both layers the fibers run essentially in the Longitudinal direction of the fabric. The layers are spaced by a series of one another Adhesive coated threads 33 disposed between the layers tied together; the adhesive is applied to the threads in such an amount that the fibers of both layers 31 and 32 become embed them in the adhesive coatings, thus creating a firm bond between the layers and the threads. the Threads 33 run transversely to the fibers of layers 31 and 32 and thus give the product tensile strength in the transverse direction; however, they are also supported by being glued to the fibers of layers 31 and 32 to increase the tensile strength in the longitudinal direction. The threads 33 do not necessarily need to be parallel to run towards each other. The threads bound by adhesive to the laid-on nonwovens can also combined with other, non-woven fibers, e.g. B. between carded fiber layers with the fibers of one layer crossing with those of the other.

If adhesive is applied to the threads 33 in such an amount that it can penetrate the nonwovens 31 and 32, and if the threads 33 are made from a plurality of highly flexible endless monofilament fibers and are soft and of little twist, so that they become when If the calendering is flattened, then on the surfaces of the fabric, as indicated at 34, embossed or pressed lines appear which are wider than the thread diameter before calendering. These lines reflect the color of the glue and possibly the color of the threads and give the impression of a more intense white than the white color of layers of bleached cotton fibers; in other words, the finished product appears to be trimmed with a pattern,
j. The reinforcement and the decorative effect can be realized on fabric products made of one or more fiber layers, regardless of whether these layers are made of weakly felted fibers, e.g. B. from carded nonwovens, as shown in Fig. 5, or are made in another way. The fiber fleece or the fiber fleeces can be composed of mixtures of different fibers; they can also contain fibers of different lengths, including those of particular length, or threads or fibers which increase the tensile strength of the composite. For example, in Fig. 5a an absorbent fiber fleece 31a is shown, which contains particularly long fibers or threads 31b in a tangled arrangement. Reinforcing threads 33a run in one direction on one side of the nonwoven fabric and reinforcing threads 33b on the other side in the transverse direction. The threads 33 a and 33 b are coated with adhesive and adhere to the nonwoven fabric; however, they can also be bound to this by adhesive fibers contained in the nonwoven fabric. If desired, a

lp ^ thread layer, for example the thread layer 33 b, as known per se, are replaced by lines of printed adhesive; the amount of adhesive printed on must be so large that adhesive penetrates into the nonwoven fabric, the fibers of which hold in their position in the nonwoven fabric and also binds the threads 33 α if the latter are not coated with adhesive. FIG. 5 a shows only a reinforcing intermediate layer of the composite according to the invention; the Vaservlies 31a, and the threads 33 a and 33 b are inserted between two or more fiber outer layers in the same way as shown in FIG. The filaments of Figure 5 have a denier on the order of about 30 to 150; they have little twist and are therefore easily flattened. These flattened areas ensure good adhesion between the threads and the nonwovens 31 and 32. If the calender pressure is light enough to preclude tight pressing of the fibers against the threads and flattening of the latter, then the threads appear only linearly on the outer surfaces of the composite material, similar to that indicated at 25 in FIG.

The parallel threads of the composite according to FIG. 5 are preferably arranged so that each fiber of the carded nonwoven fabric with at least comes into contact with an adhesive-coated thread and thereby becomes stuck in the end product is anchored. In the composite according to FIG. 1, the fibers of the individual cellulose wadding layers are

4.0 usually well anchored thanks to the manufacture of the same from a pulp, so that the anchoring of these fibers is less dependent on one Gluing each fiber to the thread structure; the latter gives strength to the cotton wool layers by that at least fibers are bound with threads by glue.

The thread structure used for reinforcement according to FIG. 5 is produced in such a way that the threads first lays it on one of the carded nonwovens and then combines the other nonwoven with it. For example As shown in FIG. 8, the carded nonwoven fabric 31 is turned into the shape of a tube a mandrel 35 brought by means of a guide funnel 36. The threads 33 are drawn off from bobbins 37 and wrapped around the nonwoven tube formed over the mandrel after being previously over adhesive application rolls 38 had run. The glue application rolls are supplied with glue from containers 39. The thread bobbins 37, the adhesive application

, So roll 38 and the glue container 39 are on one circumferential carrier 40 arranged. The thread-wrapped tube is then cut open at 41, and although along the abutting edges of the fleece 31; then the structure is unfolded into the plane; those with glue coated threads 33 are located on one side of this fabric structure. Then the other becomes Fiber fleece 32 combined with the side of the fiber fleece 31 carrying the threads, expediently using of pressure from a pair of pressure rollers. One of the types mentioned above is used as the adhesive.

When producing the composite according to FIG. 5, the calender pressure can be selected so high that not only the pattern mentioned above arises, but also a flattening and reduction in strength of the Threads transverse to the plane of the fabric to such an extent that the material thickness in the area of the threads when touched is hardly different from the thickness of the nonwovens between the threads. Here are the Components in the area of the threads more compact than between them; However, that does not mean any noteworthy Stiffening or other adverse properties of the product; on the contrary it becomes the flexibility of the material, thanks to the decrease in its thickness. Also the absorbency is increased by the more compact union of the fibers and by the creation of capillary tubes or cracks between the fibers.

When it is desired to bind more cellulose wadding or other nonwovens than through a single, adhesive-bearing thread layer would be possible, additional thread layers can be placed between others Fleeces are arranged.

The described composite can be used once and then thrown away; but it is durable enough to allow repeated use. For example, a towel made of fabric according to FIG. 1, creped or uncreped, can be used at time intervals ϊύκ-τ 1 day and then replaced by another, clean towel, while the used one is burned. This towel fabric is particularly suitable for use by children in the household; but it can also be used for industrial purposes; it has the advantage that it does not need to be washed and it has succumbed to the well-known paper towels that are readable for single use.

The composite according to the invention is also suitable for use as an apron, as a bib, as Wiping and polishing cloth, etc.

Claims (11)

Claims: * ° 1. A composite of soft, highly flexible fiber outer layers, such as crepe paper, and a reinforcing intermediate layer of spaced apart flexible threads which are glued to the fiber layers, characterized in that the reinforcing threads (6, 7 or 33 or 33 a, 33 b) are composed of highly flexible monofilejj ^^ ,, endless fibers twisted together by a weak twist. " 2. Composite according to claim 1, characterized in that the threads (6, 7 or 33 or 33a, 33 b) so flattened and with the fiber layers (1, 2, 3, 4 or 31, 32 or 31a, etc.) .) are so tightly pressed together that in the area of the threads the sum of the thicknesses of the fibers and the fiber layers is essentially not greater than the thickness of the fiber layers alone in the other areas. 3. Composite according to claim 1 or 2, characterized in that the threads (6, 7 or 33 or 33a, 33b) have a denier value in the order of 30 to 150 and a twist in the order of 0 to 6. 4. Composite according to claim 1, 2 or 3, characterized in that the threads (6, 7 or 33 or 33a, 33b) consist of two to one hundred and fifty individual fibers with a twist of not more than six turns are twisted to a length of 2.5 cm. 5. Composite according to claim 1 to 4, characterized in that the threads (6, 7 or 33 or 33 a, 33 fr) are brought up with adhesive oil, which the fibrous material layers (2, 3 or 31, 32 or 31a etc.) binds with the threads. 6. The composite according to claim 5, characterized in that the threads (6, T) are arranged in the form of a wide-meshed network (5), the threads of which intersect and which has a mesh size such that the fiber layers (2, 3) through the Are in contact with each other through the mesh. 7. Composite according to claim 5, characterized in that that the network (5) consists of two layers of intersecting threads (6, 7) 1> from where the threads (6) of one layer lie completely on one side of the threads (7) of the other layer and at least the threads (6) of the one layer are coated with adhesive, so that the threads are attached the intersections are glued together. 8. Composite according to claim 6 or 7, characterized in that parts of the threads (e.g. 6) have adhesive-free points (21) between the crossing points. 9. The composite according to claim 1 to 8, characterized in that at least one of the fiber outer layers made of a multitude of highly porous, thin layers of crepe paper placed one on top of the other (1, 2 or 3, 4) exists. 10. The composite according to claim 1 to 9, characterized in that the provided with adhesive Threads (6 or 33) run in its longitudinal direction and that it is pleated transversely to it. 11. The composite according to claim 1 to 10, characterized in that the fiber layers (31a, etc. ) contain a small proportion of tangled reinforcing fibers or threads (31b), the length of which is greater than the average length of the other fibers of the layers, and that the reinforcing threads (33 a, 33 b) cross at least part of these tangled fibers or threads (316). Considered publications:
German Patent Nos. 255 374, 534 056, ^ 577,656; ν Swiss patent specification No. 27 393;
U.S. Patent No. 2,564,689 / 1,867,071, 503 337, 1 301 605. 1 sheet of drawings © 909 507/501 4.