CA2074768C - Fleece laminate having high specific volume and good strength - Google Patents

Fleece laminate having high specific volume and good strength Download PDF

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Publication number
CA2074768C
CA2074768C CA 2074768 CA2074768A CA2074768C CA 2074768 C CA2074768 C CA 2074768C CA 2074768 CA2074768 CA 2074768 CA 2074768 A CA2074768 A CA 2074768A CA 2074768 C CA2074768 C CA 2074768C
Authority
CA
Canada
Prior art keywords
fleece
thread
laminate
filler
reinforced
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.)
Expired - Fee Related
Application number
CA 2074768
Other languages
French (fr)
Other versions
CA2074768A1 (en
Inventor
Hans Claus Assent
Manfred Jost
Jurgen Knoke
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.)
Carl Freudenberg KG
Original Assignee
Carl Freudenberg KG
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 Carl Freudenberg KG filed Critical Carl Freudenberg KG
Publication of CA2074768A1 publication Critical patent/CA2074768A1/en
Application granted granted Critical
Publication of CA2074768C publication Critical patent/CA2074768C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/10Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer reinforced with filaments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/72Density
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08Dimensions, e.g. volume
    • B32B2309/10Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105Thickness
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24074Strand or strand-portions
    • Y10T428/24091Strand or strand-portions with additional layer[s]
    • Y10T428/24099On each side of strands or strand-portions
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322Composite web or sheet
    • Y10T428/24331Composite web or sheet including nonapertured component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826Spot bonds connect components
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982Particulate matter [e.g., sphere, flake, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • Y10T442/668Separate nonwoven fabric layers comprise chemically different strand or fiber material

Abstract

ABSTRACT

A fleece laminate includes a filler fleece and a thread reinforced fleece and has a total thickness of more than 2 mm. The filler fleece has a low specific volume, a raw density of below 0.025 g/cm3 and a thickness of 1.6 to 60 mm. The thread reinforced fleece is composed of 10 to 60 g/m2 fleece material having a raw density above 0.035 g/cm3 and 3 to 100 g/m2 of a thread reinforcement. The laminate has a high strength in the warp direction. A fleece laminate of large volume is achieved without the reduction in volume and high density observed in conventional reinforced filler fleeces.

Description

2~7~7~

Fleece Laminate Havin~ Hi~h SDec~fic Volume And Good Stren~th This disclosure relates to fleeces and more particularly to thread reinforced fleeces.
In the padding art, fleeces with thread reinforcement in ~he warp direction, in warpJwoof (weft) or in warp/short woof direction have prevailed over the last years. Padding fleeces with thread reinforcement in warp/woof direction are disclosed in EP-A 0 119 754.
The required technology i3 described in the publication CHEMIEFASERN/TEXTILINDUSTRIE 39, 91, (Msi 19~9), 5124. ~owever, neither of these publications refer to laminates which consls~ of a filler fleece wlthout thread reinforcement having a raw density below 0.025 g/cm3 and of a thread reinforced fleece having a raw density (without reinforcement) of above 0.035 g/cm3.
Warp reinforced fleeces have a wider area of application than regular fleeces due to their greater strength and smaller stretch in the direction of the reinforcement. This is important, for Qxample, for waist band paddings where great strength and short s~retch in longitudinal direction of the waist band arP required. The list or edging of wool coats is a similar area where the use of a fleece is especially advantageou~ (little reclinching, relatively high volume at low weight, etc.). However, the strength of a regular fleece in direction of the border or edge is insufficient and only the reinforcement with warp threads permits the use of a Pleece in this application. Fleece reinforcements in warp/short woof and warp/woof direction are also of interest for other applications. The increased strength in one direction of a warp reinforced fleece is primarily of interest in the placket art where the fleece is used as placket reinforcement. When such materials are used as filler fleece-q for anoracs, winter clothing, etc... they are distinguished from simple non-reinforced filler fleece~ by their technical advantage~.
Generally, when relnforcement in warp, warp/woof9 or warp/short woof direction is used, a striking reduction is observed in the filler fleece volume, resulting in increased density. This has two aggravating disadvantages:

~7~76~

1. As a consequence of the reduc~ion in volume, more fibers are required to produce the same fleece volume (significant increase in costs).
2. Thick filler fleeces of more than 1 cm thicXness can not be warp S reinforced, since this is not pos~ible with conventional machines.It is now an ob~ect of the present disclosure to describe a fleece laminate made of a filler fleece and a thread reinforced fleece which laminate has a total thickness of more ~han 2 mm. It is another object to disclose a thread reinforced laminate of high strength in warp direction or in both directions without the volume reduction prevlously observed with conventional reinforced filler fleeces. It is yet another ob~ect to disclose a laminate whereon this large volume is achieved with as few inserted reinforcement threads as possible.
These ob~ects are achieved in a laminate comprising a filler fleece with a thread reinforced fleece laminated to it. The laminate has a total thickness of more than 2 mm, in which the upper limit can be selected according to the requirements of the user. The filler fleece has a low specific volume, a raw density below 0.025 g/cm3 and a thickness above 0.6 ~m, so that the upper limit which can still be processed will be about 60 mm. The filler fleece includes no thread reinforcement. The thread reinforced fleece is a combination of a 10 to 60 g/m2 fleece having a raw density above 0.035 g/cm3 and 3 to 100 g/m2 thread reinforcement. The thread relnforcement may be positioned inside or on the surface of the lamlnate.
Since it is one of the ob~ects to achleve a high volume fleece, the laminating must be carried out in such a way that preferably there is no volume reduction. For this purpose, the layers of the laminate should be laminated in the heating zone not under pressure but with an intermediate gap. A laminate produced in this way can be used without adhesive, but may be provided with an adhesive applied in point form on the side of the thread reinforced fleece if the lamlnate is to be used as fixing padding. The laminating must be carried out in such a way that as much volume as poasible is maintained. To achieve this, the thread reinforced fleece may be provided on at least one surface with a hot melt adhesive applied in point form, with a continuously applied adhesive powder, or with an air permeable adhesive net. In all these 2~7'~7~8 cases, a continuous press may be used for the lamlnating process and the solidification must occur with as little pressure as possible.
High frequency vibrating or hot melt needles which penetrate the thin reinforced fleece up to the surface of the filler fleece may also be used. In these latter cases, the fibers used for the filler fleece and the thread reinforced fleece must be thermoplastlc. Materials of this type may be used especially in paddlng for clothlng. They may also be used for the filling of bedding material and advantageously combine strength and volume.
The use of charmeuse as a covering for filler fleeces to improve fiber migration is already known in the padding art. However, the laminate described herein has the following advantages over that combination:
1. The strength in direction of the thread reinforcement is greater than with the use of charmeuse; and 2. The fiber migration of an open charmeuse covering relatively to the covered filler fleeces after a series of tests is only marginally improvedl while the thread reinforced fleece provides much better protection because no holes are present.
To achieve a combination of softness, strength and minimal fiber migration, it may be desired in some cases to cover a voluminous fleece on both sides with a thread reinforced thin fleece material or on one side with a thread reinforced and on the other side with a non-reinforced fleece. ~owever, in each of these cases, a novel laminate is achieved which includes a filler fleece without thread reinforcement and a thread reinforced fleece. Thus the intended ob~ects are achieved with these laminates and the volume of the laminate is maintained while the strength distribution is anisotropic.
Example A filler fleece was made as ~ollows:
100 g/m2 polyester fibers 3.3 dtex were laid down under transverse carding and sprayed on both sides with 8 g/m2 of a solid polyacrylate binder with methylol acrylamide groups, dried, and the binder coalesced at 160C. This fleece was rolled and had a thickness of about 13 mm, 35 measured according to DIN 53855, part 2.
A thread reinforced fleece was manufactured as follows:

2(37~7~i8 25 g~m2 of a 100% nylon 6-fleece was lald down under transverse carding and solidifi~d to a fleece by using a point weld calender at 200C. This fleece was rolled and subsequently covered with 12 g/m2 of a copolyester hot melt adhesive applied in point form. The fleece was reinforced by shootlng through it kno~n polyester warp threads 50f22 at a density of 3.6/cm. The resulting warp reinforced fleece was printed on one side with a copolyester hot melt adhesive of 12 g/m2 applied in point form.
These two fleece materials were laminated in a ~eyer continuous press in such a way that ~he adhesive side of the thread reinforced fleece came to lie against the fi$1er fleece. The temperature on the side of the thread reinforced fleece was 160C and on the filler fleece side 180C. The speed of the laminate in the press was 10 meters per minute. The heating zone had a length of 2.5 m. The layers were not laminated under pressure but with an intermediate gap to maintain the combined volume of the layers throughout the fixation process as high as possible.
The single attached drawing shows a cross-section through a laminate of the principal construction disclosed herein, wherein the base fleece 1 has a warp reinforcement 2 and i9 laminated with the filler fleece 4 by way of an adhesive 3 applied in point form.

Claims (8)

1. A textile laminate comprising a filler fleece without thread reinforcement having a low specific volume and a thread reinforced fleece, the thread reinforced fleece being laminated with the filler fleece, the laminate having a total thickness of more than
2 mm, the filler fleece having a raw density below 0.025 g/cm3 and a thickness of 1.6 mm to 60 mm and the thread reinforce fleece being made of 10 to 60 g/m2 fleece material and having a raw density of above 0.035 g/cm3 and 3 to 100 g/m2 thread reinforcement.
2. A laminate as defined in claim 1, including an adhesive applied in point form or continuously onto the outside of the thread reinforced fleece interconnecting said filler fleece and said thread reinforced fleece.
3. A laminate as defined in claim 1 or 2, the thread reinforced fleece having said thread reinforcement in warp direction only.
4. A laminate as defined in claim 1 or 2, the filler fleece and the thread reinforced fleece being interconnected by a hot melt adhesive applied in point form.
5. A laminate as defined in claim 1 or 2, the filler fleece and the thread reinforced fleece being interconnected by a continuously applied hot melt powder.
6. A laminate as defined in claim 1 or 2, the filter fleece and the thread reinforced fleece being interconnected by an adhesive net of relatively low melting temperatures.
7. A laminate as defined in claim 1 or 2, wherein the filler fleece and the thread reinforced fleece comprise thermoplastic fibers welded together.
8. A laminate as defined in claim 7, the filler fleece and the thread reinforced fleece being needled together.
CA 2074768 1991-07-30 1992-07-28 Fleece laminate having high specific volume and good strength Expired - Fee Related CA2074768C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19914125151 DE4125151C2 (en) 1991-07-30 1991-07-30 Non-woven laminate with high specific volume and good strength
DEP4125151.2 1991-07-30

Publications (2)

Publication Number Publication Date
CA2074768A1 CA2074768A1 (en) 1993-01-31
CA2074768C true CA2074768C (en) 2000-01-25

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2074768 Expired - Fee Related CA2074768C (en) 1991-07-30 1992-07-28 Fleece laminate having high specific volume and good strength

Country Status (9)

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US (1) US5236770A (en)
EP (1) EP0525291B1 (en)
JP (1) JPH0796745B2 (en)
AT (1) ATE163151T1 (en)
BR (1) BR9202924A (en)
CA (1) CA2074768C (en)
DE (2) DE4125151C2 (en)
DK (1) DK0525291T3 (en)
ES (1) ES2114542T3 (en)

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US6547915B2 (en) 1999-04-15 2003-04-15 Kimberly-Clark Worldwide, Inc. Creep resistant composite elastic material with improved aesthetics, dimensional stability and inherent latency and method of producing same
US6638605B1 (en) 1999-11-16 2003-10-28 Allegiance Corporation Intermittently bonded nonwoven disposable surgical laminates
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US7601657B2 (en) 2003-12-31 2009-10-13 Kimberly-Clark Worldwide, Inc. Single sided stretch bonded laminates, and methods of making same
US7651653B2 (en) 2004-12-22 2010-01-26 Kimberly-Clark Worldwide, Inc. Machine and cross-machine direction elastic materials and methods of making same
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Also Published As

Publication number Publication date
ES2114542T3 (en) 1998-06-01
DK0525291T3 (en) 1998-09-23
CA2074768A1 (en) 1993-01-31
JPH0796745B2 (en) 1995-10-18
US5236770A (en) 1993-08-17
DE4125151C2 (en) 1994-09-29
DE4125151A1 (en) 1993-02-04
EP0525291B1 (en) 1998-02-11
JPH05230755A (en) 1993-09-07
DE59209193D1 (en) 1998-03-19
BR9202924A (en) 1993-03-30
EP0525291A1 (en) 1993-02-03
ATE163151T1 (en) 1998-02-15

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