[go: up one dir, main page]

WO2009052483A2 - Composites unitisés utilisant des couches rétractables pour obtenir un volume et une texture de surface - Google Patents

Composites unitisés utilisant des couches rétractables pour obtenir un volume et une texture de surface Download PDF

Info

Publication number
WO2009052483A2
WO2009052483A2 PCT/US2008/080479 US2008080479W WO2009052483A2 WO 2009052483 A2 WO2009052483 A2 WO 2009052483A2 US 2008080479 W US2008080479 W US 2008080479W WO 2009052483 A2 WO2009052483 A2 WO 2009052483A2
Authority
WO
WIPO (PCT)
Prior art keywords
unitized composite
composite web
unitized
layer
web according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2008/080479
Other languages
English (en)
Other versions
WO2009052483A3 (fr
Inventor
James P. Hanson
Larry L. Pio
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marketing Tech Service Inc
Original Assignee
Marketing Tech Service Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Marketing Tech Service Inc filed Critical Marketing Tech Service Inc
Publication of WO2009052483A2 publication Critical patent/WO2009052483A2/fr
Publication of WO2009052483A3 publication Critical patent/WO2009052483A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06J—PLEATING, KILTING OR GOFFERING TEXTILE FABRICS OR WEARING APPAREL
    • D06J1/00—Pleating, kilting or goffering textile fabrics or wearing apparel
    • D06J1/12—Forms of pleats or the like
    • 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
    • D04H1/559—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 the fibres being within layered webs
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/76—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres otherwise than in a plane, e.g. in a tubular way

Definitions

  • the present invention relates to manufacture of unitized composite structures utilizing one or more shrinkable layers to achieve raised three dimensional surface texture and bulk.
  • Fibers used in nonwovens manufacture are normally selected to assure that a flat, uniform, stable fabric will be produced in the manufacturing process. Fibers that have an undesirable tendency to shrink are often blended with non-shrinking fibers, such as wood pulp, in ratios sufficient to mask or reduce the shrinking tendency of such fibers and the final nonwoven fabric produced from them.
  • Adding raised three dimensional surface texture to a nonwoven fabric normally requires an undesirable separate step in the manufacturing process such as deep embossing that can increase density and reduce bulk of the finished fabric
  • Other known methods of imparting raised elements and three dimensional raised structures in a fabric include use of creping, corrugation and similar mechanical processes which may also produce undesirable reductions in the fabric strength.
  • some known methods for making high bulk nonwovens involve exploitation of different shrinking properties of nettings and fibrous assemblies when activated in an oven which are known technologies that have been historically practiced as a way to achieve bulk and overall fabric texturing in both paper and nonwovens.
  • a simplified manufacturing method for directly producing fabrics with a raised, mound-like randomly-textured surface has been discovered using conventional short fiber airlaid process equipment and commonly available materials to achieve a desirable three dimensional texture on selected surfaces or interior layers of composite fabrics without undesirable strength loss, bulk loss or complex manufacturing steps.
  • a layered assembly of loose elements is prepared by depositing layers of fibrous elements or other materials, at least one of the layers comprising fibrous elements or other material having a tendency to contract relative to the fibers or other material in another layer of the assembly when the assembly is exposed to an activation step such as exposure to an elevated temperature.
  • the activation step causes the shrinkable element layer(s) to contract relative to the non- shrinkable layer(s) and to pucker into raised mound-like structures during the activation step.
  • the method results in an internally bonded unitized composite with z-direction raised structures bonded securely to the other elements in the assembly when removed from the activation step.
  • layers of synthetic fibers that contract when activated by heat or some other activation process will cause adjacent non- contracting layers of fibers to develop a three dimensional texture via a bunching effect in the overall structure when activated.
  • the textured layers may be surface layers or may be in the internal layers of the unitized composite fabric after activation.
  • the contracting layer element(s) can be diluted with other non-contracting elements to the extent that the contracting effect remains but is reduced.
  • the contracting tendency and resulting three dimensional surface texturing of the contracting elements can be altered by application of machine direction tension to the assembly during activation.
  • fabrics made with this method can be beneficially used for surface cleaning applications, such as floor mop applications, wiper applications both dry and wet, and many other cleaning pad applications.
  • a fabric made with this method can be used beneficially in skin care applications.
  • a fabric made with this method can be used in filter applications.
  • a fabric made with this method can be used for visually appealing applications, such as window covers, table covers, office partitions, room dividers, or for artistic applications.
  • a fabric made with this method can be used for hygienic products, for example: feminine products, diapers, adult incontinence products, and bandages.
  • a fabric made with this method can be used for cushioning applications.
  • a fabric made with this method can be used for insulative applications.
  • fabrics of this type can be produced on airlaid machines, or other machines capable of making similar fabrics, such as a carding machine.
  • a fiber assembly with these layer(s) may be optionally shaped into a wave-like fabric prior to activating.
  • a fabric with contractible elements in one or more layers will tend to contract in both the machine direction and the cross machine direction.
  • the raised texturing can be beneficially altered by adjusting the machine direction tension applied to the assembly during the activation process.
  • functional attributes such as scrubbiness, can be included in one or more surface layers if desired.
  • particles may be added to the fabric to provide additional functional attributes.
  • Figure 1 shows an airlaid assembly of loose fiber layers which are optionally compressed.
  • Figure 2 shows an assembly of loose fibers which are subsequently bonded into a unitized composite in an activation step.
  • Figure 3 shows a flow chart of a process for forming unitized composite according to aspects of this invention.
  • Figure 4 shows a method of forming a unitized composite by depositing loose fiber assemblies which are shaped into a wave-like form using a transfer device raised in the z-direction relative to the oven wire and with the oven wire moving at a lower speed to impart wave-like shaping to the entire assembly prior to activation.
  • Figure 5 shows a wave-like shaped assembly and the x, y, and z directional conventions used herein.
  • Figure 6 is a photograph of the top surface of a fabric containing powdered materials within the assembly, using the texturing method of the invention.
  • Figure 7 is a photomicrograph of the cross machine profile of the fabric of Figure
  • Figure 8 is a photograph of the top surface of a 3-layered fabric with top and bottom surfaces textured using the method of the invention.
  • Figure 9 is a photograph of the bottom surface of the fabric of Figure 8.
  • Figure 10 is a photomicrograph of the cross machine profile of the fabric of Figure
  • Figure 11 is a photograph of the top surface of a 5-layered fabric made using the texturing method of the invention when the assembly has been formed into a wave-like shaping prior to activation.
  • Figure 12 is a photograph of the bottom surface of the fabric of Figure 11.
  • Figure 13 is a microphotograph of the edge of the fabric cut in the machine direction of the fabric of Figure 11.
  • nonwoven means a web having a structure made of individual fibers which are interlaid, but not in an ordered or identifiable manner such as occurs in a woven or knitted web.
  • nonwoven fabrics are generally "sheet or web structures bonded together by entangling fibers or filaments (and by perforating films) mechanically, thermally or chemically. They are flat, porous sheets that are made directly from separate fibers or from molten plastic or plastic film. They are not made by weaving or knitting and do not require converting the fibers to yarn.”
  • Nonwoven webs are formed from many processes, such as, for example, airlaying, carding, meltblowing, spunbonding, co-forming, wet forming, scrim and netting extrusion, perforated films, and other such processes.
  • airlaid implies that a nonwoven web is formed by a dry air-laying process, which deposits assemblies of loose fibers on a substrate such as a porous collecting wire in layers.
  • short fiber airlaid process refers to a type of dry air-laying process which was originally developed to process relatively short wood pulp fibers for producing disposable fabrics, like high bulk towels and feminine napkin absorbent media. Typical machines used for an air-laying process are supplied by Dan Web A/S and Oerlikon Neumag Denmark A/S of Denmark.
  • bi-component fiber or “multi-component fiber” refers to a fiber having multiple components such as fibers comprising a core composed of one material (such as a polymer) that is encased within a sheath composed of a different material (such as another polymer with a different melting point).
  • a sheath composed of a different material
  • Some types of "bi- component” or “multi-component” fibers can be used as binder fibers that can be bound to one another and to fibers or components to form a unitized structure. For example, in a polymeric fiber, the polymer comprising the sheath often melts at a different, typically lower, temperature than the polymer comprising the core.
  • binder fibers provide thermal bonding after appropriate activation, such as by heating in an oven and subsequent cooling, due to melting the sheath polymer, while retaining the desirable fibrous structure characteristics of the core polymer.
  • mono- and multi-component filaments, extrusions, films, scrims, netting, particles, powders, emulsion polymers and resins in numerous chemistries can also be used to bond fibrous structures, in addition to mechanical bonding methods such as needlepunching and hydro-entangling.
  • Composite assemblies are optionally made by including other loose fiber assembly techniques, such as carding techniques, or by including direct process nonwovens methods, such as spunbonding, meltblowing, spunmelting, co-forming, extrusions, or with scrims and films or other techniques. These combinations in layered assemblies can be subsequently bonded together to produce a unitized composite structure using an oven or other activation step to cause the layers to adhere to each other becoming a unitized composite after activation
  • the term "element” refers to one individual component of a structure, assembly, composite, or lamination, i.e., a layer, fiber, particle, filler, or any other component that can be incorporated (e.g., fusion bonded, adhesively bonded, physically bonded by entanglement or the like, or occluded within) into a unitized structure, assembly, composite, or lamination.
  • the term “assembly” refers to a deposition of loose fiber elements or a layered combination of two or more elements of a structure.
  • unitized structure or “unitized composite” refer interchangeably to the structure resulting from bonding assemblies in an oven or other device which causes the layers of an assembly to bond together.
  • wave-like is used to describe the general shaping of assemblies characterized by a substantially periodic waveform, but not necessarily sinusoidal, perfectly repeating, easily seen, or perfectly parallel, that may be further characterized in terms of wavelength and amplitude, the wavelength being the distance between repeating units of a wave pattern (e.g., measured from one crest to the next crest, or from one trough to the next trough) and the amplitude being the height of the undulations.
  • wavenumber which is inversely related to wavelength and refers to the number of repeating units of a wave pattern per unit length.
  • the wavenumber is the spacial analogue of frequency.
  • the wave-like form need not be perfectly recurring, i.e., there may be some change in size, shape, or other variation of the generally recurring waveforms.
  • Such wave-like form is depicted generally in an idealized form by 2100 in Figure 5, and a typical wave form is shown in the photomicrograph of Figure 6.
  • activation may be any process, whether with a heated oven, by radiation of electromagnetic energy, or by some other method, which causes shrinkage of the shrinkable elements and bonding to occur between elements and layers when cooled or otherwise removed from activation.
  • the term "recipe" refers to a specific formula of a mixture of various components used in an assembly, including the type and amount of each component.
  • Figure 1 shows a schematic representation provided as an exemplary system that can be used to form a unitized airlaid composite according to aspects of this invention.
  • Exemplary short fiber airlaid process machinery suitable for the practice of the present invention is available for public use at Marketing Technology Service, Inc. of Kalamazoo Michigan USA, or through Dan Web A/S of Aarhus, Denmark and Oerlikon Neumag
  • Figure 1 provides a schematic side view of an exemplary web and complimentary web forming systems showing how layers are deposited on top of each other while moving through respective web-forming systems.
  • the layers of the exemplary webs are not depicted to any particular proportion or scale, but are instead shown schematically for purposes of illustration only. Also, because of some mixing and blending of fibers between the layers of a unitized airlaid structure that occurs during the web-forming process, the layers are not perfectly distinct as depicted in the figures.
  • the web forming system illustrated in Figure 1 shows a machine 1004a having a conveyor surface 1020 which is a porous wire screen 1006 on which the web of the airlaid composite is formed.
  • Fiber-introducing heads 1012, 1014, 1016 and 1018 are positioned above the wire screen in order to deliver the components of the airlaid composite to the screen in a controlled manner.
  • the fiber-introducing heads are configured to introduce the same or different fibers in any combination, as depicted by crosshatching.
  • two or more (or all) of the heads can introduce the same fibers or fiber mixture, or all or some of the heads can introduce different fibers or fiber mixtures.
  • Rolls 1008 and 1010 are also provided in order to selectively modify the web as it passes through the forming system.
  • the schematic representation of the resulting web of the unitized airlaid composite shows the web portions 1000a provided by each of the heads as those portions build to form the web of the unitized airlaid composite along the machine direction (MD). Again, the web portions can be intermingled at the interfaces between layers in actual airlaid systems as opposed to the distinct zones depicted for purposes of illustration.
  • one exemplary system utilizes a machine 1004a to form a web of an airlaid composite 1000a.
  • the machine 1004a includes a conveyor mechanism 1006 that supports a wire screen 1020 on which the components of the airlaid composites are deposited.
  • a pair of upstream rolls 1008 and another pair of downstream rolls 1010 are provided in such a way that the wire screen 1020 passes between each pair of rolls 1008 and 1010.
  • Multiple heads 1012, 1014, 1016 and 1018 are provided above the wire screen 1020 along the length of the machine 1004a.
  • Illustrated machine 1004a includes four (4) heads, including a first head 1012, a second head 1014, a third head 1016, and a fourth head 1018.
  • First and second heads 1012 and 1014 are positioned upstream from the upstream rolls 1008, and third and fourth heads 1016 and 1018 are positioned downstream from the upstream rolls 1008, and upstream from downstream rolls 1010.
  • the upstream and downstream sets of rolls 1008 and 1010 are optionally utilized as compression rolls.
  • the gap between the rolls 1008 and the gap between the rolls in 1010 is adjustable.
  • the machine 1004a illustrated in Figure 1 is shown to have heads 1012, 1014, 1016, and 1018 feeding substantially equal amounts of the same fiber composition.
  • heads 1012, 1014, 1016, and 1018 optionally feed substantially different amounts of fibers or feed substantially different fibers or fiber compositions.
  • the machine 1004a does not utilize upstream and downstream rolls 1008 and 1010 as compression rolls (i.e., the gaps between the compression rolls of 1008 and of 1010 are maintained so as to eliminate or minimize compression of the web passing between them). Accordingly, the machine 1004a is configured to yield a relatively thick fabric having a relatively low density. Skilled practitioners will utilize the compression rolls to achieve desired fabric attributes.
  • Figure 2 shows an exemplary assembly 2310 of loose fiber layers 2306, 2307,
  • FIG. 3 is a flow chart 800 of exemplary steps for fabricating a unitized airlaid composite in accordance with one embodiment of the present invention.
  • Block 802 illustrates the step of depositing a first quantity of fibers so as to define a layer.
  • Block 804 illustrates the step of depositing a second quantity of fibers onto the first quantity of fibers, wherein the second quantity of fibers is layered on top of the first quantity of fibers to form contacting unbonded, but relatively discrete, layers.
  • Block 806 illustrates the step of depositing an additional concentration(s) of fibers to further construct multiple layers.
  • Block 807 illustrates the additional optional step of shaping the layer assembly into a wave-like form.
  • Block 808 illustrates the final step of activating and bonding the assemblies of fibers together to form a unitized composite structure.
  • Figure 4 illustrates practice of one method for shaping the airlaid layered assembly prior to the activation step, using a raised transfer wire device such as is offered for sale by Dan Web A/S of Aarhus, Denmark.
  • the transfer device functions by employing a suction box 3264 to provide vacuum through a moving porous wire belt 3210 closely synchronized in speed to both the oven wire 3259 and the forming wire 1006.
  • the function of the transfer wire in normal operation is to lift the fragile loose fiber assembly from the forming section wire and then deposit the assembly - intact - onto the oven wire where subsequent activation and bonding will occur.
  • the oven wire is slowed, and the transfer wire device optionally raised to control the shaping.
  • Figure 5 shows a three-dimensional view of a wave-like element 2100. Such a structure is thicker and lower in overall density relative to a flat surface of similar formulation.
  • Figure 5 also provides a reference to demonstrate the x, y, and z direction conventions that are referred to herein, showing the length 2104 (x or machine direction), width 2103 (y or cross machine direction) and vertical height 2102 (z direction) of a continuous assembly.
  • Table 1 lists the components of an exemplary fabric using the invention to make a floor mop fabric with a scrubby surface. Table 1
  • the bottom layer (to be contacted against the floor surface) is a layer of FiberVisions' 3.3 dtex AL-Delta II fiber (a bi-compoent fiber having a polypropylene core and a polyethylene sheath).
  • the Fibervisions AL-Delta II bonding fiber manufactured by Fibervisions A/S of Varde, Denmark, is utilized by the present invention in an unconventional way to achieve a scrubby / abrasive effect on the fabric surface.
  • a bi- component bonding fiber is normally utilized as a minority component in an airlaid fabric for development of strength when activated.
  • the AL-Delta II fiber contracts, and exhibits the abrasive effect when used as a majority component of a surface layer, when the fabric is heated near, at, or above the melting temperature of the polymer used in the core of the bonding fiber which would not be normally done according to normal bonding procedures used for it's bonding function .
  • Dilution of the surface abrasive layer with other materials, for example other bonding fibers, or other non-bonding synthetic or natural fibers may be used to control shrinkage, to temper the abrasive effect, or provide a secondary abrasive component (as for example using polyester or metal fibers) or other functional attributes, such as absorbency, or fire retardency etc.
  • the inside layer(s) of the exemplary floor mop or wiping structure of Table 1 include wood pulp with a conventional bi-component bonding fiber having a polyester core and a lower melting temperature polyester sheath (for example, Trevira type 255, 1.7 dtex, manufactured by Trevira GmbH of Bobingen, Germany).
  • a conventional bi-component bonding fiber having a polyester core and a lower melting temperature polyester sheath
  • an absorbency aid such as superabsorbent polymer (SAP) or superabsorbent fiber (SAF) may also be used for the applications.
  • super absorbents polymer particulates include those formed from hydrolyzed cross-linked polyacrylamides, polyacrylates, polymers of acrylic polymers, or their copolymers.
  • a top or intermediate layer made of predominantly a shrinking bonding fiber such as Fibervisions ALAD 1.7 dtex bi-component fiber (having a polypropylene core and a polyethylene sheath) optionally improves the surface strength of the fabric and provides the mode of texturing the fabric.
  • the exemplary floor mop product of Table 1 may be optionally shaped by waving technology prior to activation to provide raised and recessed regions where dirt materials can be trapped, and also increasing the net pressure (by reducing the overall contacting surface area) achieved by localized areas of the fabric in contact with the surface to be cleaned.
  • the floor contacting surface of the floor mop product of Table 1, whether shaped additionally by optional pre-activation waving technology, can be further modified by selection of activation step parameters, such as, in the case of an oven activation step, air pressure applied to the airlaid fabric against the oven wire (in a through air oven), oven temperature, and the application of suitable tension on the web as it exits the activation step, for example an oven, prior to cooling. Cooling of the sheet after any shaping and activation is then required to preserve the desirable shaping. Any lamination steps would be done after the fabric has been cooled.
  • activation step parameters such as, in the case of an oven activation step, air pressure applied to the airlaid fabric against the oven wire (in a through air oven), oven temperature, and the application of suitable tension on the web as it exits the activation step, for example an oven, prior to cooling. Cooling of the sheet after any shaping and activation is then required to preserve the desirable shaping. Any lamination steps would be done after the fabric has been cooled.
  • Table 2 lists the component layers of an exemplary fabric suitable for use in wiping and cleaning pad applications. Table 2
  • Layer 3 (Top Layer): Trevira 1.7 dtex Type 255 bonding fiber 50% Wellman Fortrel 6.67 dtex PET fiber 50%
  • Layer 1 (Bottom layer): Trevira 1.7 dtex Type 255 bonding fiber 50% Wellman Fortrel 6.67 dtex PET fiber 50%
  • the fabric can be made with one or both surfaces having the shaped texture by use of one or more fibers providing the shrinking characteristics, such as the AL-Delta II fiber, for the shrinking untextured layer. It is often desirable in wipe and cleaning pad applications to reduce or eliminate the wood pulp fraction and to replace that portion of the textured layers with typically used synthetic fibers, such as a Fortrel 6.67 dtex polyethylene terephthalate PET, as manufactured by Wellman, Inc. of Fort Mill, South Carolina, or to replace a portion of the internal layers with additional bonding fiber, in both cases to inhibit potential linting , improve bulk, and to maintain fabric strength for repeated use cycles when wiping or scrubbing.
  • Table 3 lists the component layers of an exemplary fabric for use as a lamp shade or window covering. Table 3
  • Layer 3 (Top Layer): Trevira 1.7 dtex Type 255 bonding fiber 60% Wellman Fortrel 6.67 dtex PET fiber 40%
  • Layer 1 (Bottom layer): Trevira 1.7 dtex Type 255 bonding fiber 60% Wellman Fortrel 6.67 dtex PET fiber 40%
  • Fibervisions ALAD for the shrinking layers, provides texture to the non- shrinking layers comprised of the bi-component Trevira bonding fiber, and the Fortrel PET. Colored fibers with similar attributes to these fibers could provide additional decorative attributes with this, and with other uses noted in the invention.
  • Tables 2 and 3 is suitably applied for many other uses, including visual, artistic and decorative purposes, and for improving softness and drape.
  • Table 4 lists the component layers of an exemplary 4-layer fabric, which can be used as an absorbent hygienic product. Table 4
  • the bottom layer uses only Fibervisions ALAD 1.5 denier bonding fiber.
  • the second layer contains super absorbent particles, wood pulp and Trevira 1.5 denier bonding fiber.
  • the third layer contains Fortrel 3.0d PET fiber and Trevira 1.5 denier bonding fiber.
  • the top layer uses only Trevira 1.5 denier bonding fiber.
  • the inside layers and the top layer are textured due to the shrinkage of the bottom layer.
  • Figure 6 is a photograph of the top surface of the fabric as described in Table 4, showing the texturing of this fabric. The bottom surface of this fabric is flat.
  • Figure 7 is a photomicrograph of the cross machine profile of the fabric of Table 4.
  • Figure 8 is a photograph of the top surface of a 3 -layered fabric with both the top and bottom surfaces textured using the method of the invention.
  • the top layer of fibers is a blend of 60% Tencel 6mm fibers available from Lenzing Fibers Ltd. of Grimsby, UK, with 40% 1.5 denier Trevira bonding fiber.
  • the middle layer is a blend of 60% Delta II 6 denier bonding fibers with 40% ALAD 1.7 denier bonding fibers.
  • the bottom layer is also 60% Tencel 6 mm fibers, with 40% 1.5 denier Trevira bonding fiber.
  • the shrinking of the Delta II / ALAD middle layer occurs primarily in the cross machine direction, which is the predominant mode of shrinkage in assemblies that have not been shaped by using a waving technique.
  • Figure 9 is a photograph of the bottom surface of the fabric of Figure 8. Note the surfaces are somewhat different, even though the formulas are the same.
  • Figure 10 is a microphotograph of the cross machine profile of the fabric of Figure
  • Figure 10 displays the textured top and bottom surfaces, and the flat middle layer.
  • Figure 11 is a photograph of the top surface of a 5 -layered fabric of an exemplary pre-waved fabric, which also uses the texturing method of the present invention.
  • the bottom layer consists of a blend of 25% Kosa 255 2.2 denier bonding fiber available from Invista Sari of Charlotte, NC and 75% 0.8 denier Wellman PET fiber.
  • the second layer is Delta II 6 denier bonding fiber.
  • the third layer is 30% Trevira 1.5 denier bonding fiber blended with 70% 8.0 denier Wellman PET.
  • the fourth layer is Delta II 6 denier bonding fiber.
  • the top layer is 60% Trevira 1.5 denier bonding fiber with 40% Tencel.
  • layers 2 and 4 are providing shrinking forces both in the machine and cross machine directions due to waving technique used in addition to the texturing method of this invention.
  • Figure 12 is a photograph of the bottom surface of the fabric of Figure 11.
  • Figure 13 is a photomicrograph of the edge of the fabric of Figure 11 cut in the machine direction. This photomicrograph displays the waved layers, especially the denser layers 2 and 4.
  • FIG. 13 is a photomicrograph of the edge of the fabric of Figure 11 cut in the machine direction. This photomicrograph displays the waved layers, especially the denser layers 2 and 4.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne une technique de fabrication simplifiée pour former directement des structures composites unitisées qui présentent éventuellement au moins une surface relativement plate et qui présentent au moins une surface comportant des éléments présentant la forme de monticules dans un composite unitisé à assemblage interne. Une matrice de fibres et d'autres éléments matériels est déposée dans des couches non assemblées. Au moins un élément est composé d'un matériau de contraction qui se rétracte par rapport à d'autres composants lorsqu'il est activé, comme lors du chauffage dans un four, pour devenir un composite unitisé à assemblage interne avec une texture présentant la forme d'un monticule soulevé dans une direction z après l'étape d'activation. L'invention concerne les applications du produit fini et des bandes composites unitisées adaptées aux produits finis utilisant les inventions.
PCT/US2008/080479 2007-10-19 2008-10-20 Composites unitisés utilisant des couches rétractables pour obtenir un volume et une texture de surface Ceased WO2009052483A2 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US98125507P 2007-10-19 2007-10-19
US98126807P 2007-10-19 2007-10-19
US60/981,268 2007-10-19
US60/981,255 2007-10-19

Publications (2)

Publication Number Publication Date
WO2009052483A2 true WO2009052483A2 (fr) 2009-04-23
WO2009052483A3 WO2009052483A3 (fr) 2009-06-04

Family

ID=40568103

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2008/080479 Ceased WO2009052483A2 (fr) 2007-10-19 2008-10-20 Composites unitisés utilisant des couches rétractables pour obtenir un volume et une texture de surface

Country Status (1)

Country Link
WO (1) WO2009052483A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010047639A3 (fr) * 2008-10-23 2010-06-10 Vikan Ab Balai-éponge jetable

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR930006226B1 (ko) * 1990-07-20 1993-07-09 한국전기통신공사 디지틀 단안정 멀티바이브레이터
US6207602B1 (en) * 1994-11-23 2001-03-27 Bba Nonwovens Simpsonville, Inc. Nonwoven fabrics and fabric laminates from multiconstituent polyolefin fibers
JP4320078B2 (ja) * 1999-02-15 2009-08-26 大和紡績株式会社 嵩高性不織布、その製造方法およびこれを用いた清拭材
US6893522B1 (en) * 1999-10-05 2005-05-17 Polymer Group, Inc. High bulk non-woven composite fabric
JP3658301B2 (ja) * 2000-08-31 2005-06-08 ユニ・チャーム株式会社 弾性伸縮性を有する複合シートの製造方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010047639A3 (fr) * 2008-10-23 2010-06-10 Vikan Ab Balai-éponge jetable

Also Published As

Publication number Publication date
WO2009052483A3 (fr) 2009-06-04

Similar Documents

Publication Publication Date Title
EP2026958B1 (fr) Tissu composite integre a ondulations dans le sens transversal de la machine et procedes pour le realiser
US6588080B1 (en) Controlled loft and density nonwoven webs and method for producing
KR101019805B1 (ko) 터프트화된 섬유질 웨브
US7955455B2 (en) Wave-like structures bonded to flat surfaces in unitized composites and methods for making same
EP1591575B1 (fr) Feuille volumineuse et son procédé de fabrication
US7682686B2 (en) Tufted fibrous web
KR100761571B1 (ko) 터프트 형성된 섬유질 웨브
CN100522119C (zh) 簇状纤维网
US6635136B2 (en) Method for producing materials having z-direction fibers and folds
WO2000066057A1 (fr) Tissus comportant des fibres et des plis disposes dans le sens z, et procede de production desdits tissus
JP2020519781A (ja) 水流交絡エアレイドプロセスおよび産業用ワイプ製品
KR20080073347A (ko) 부직포 제품을 위한 시이트 분할 성형 벨트
US8440123B2 (en) Unitized composites utilizing melted synthetic fibers to achieve rough or abrasive attributes and decorative effects
WO2001074281A1 (fr) Materiaux presentant des fibres et des plis en sens z et leur procede de production
US20080311350A1 (en) Unitized composites utilizing shrinkable layers to achieve surface texture and bulk
WO2009052483A2 (fr) Composites unitisés utilisant des couches rétractables pour obtenir un volume et une texture de surface
GB2387180A (en) A lofted non-woven material with z orientated fibres

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 08839349

Country of ref document: EP

Kind code of ref document: A2

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 08839349

Country of ref document: EP

Kind code of ref document: A2