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Publication numberUS3439085 A
Publication typeGrant
Publication dateApr 15, 1969
Filing dateOct 21, 1964
Priority dateOct 25, 1963
Also published asDE1282590B, DE1282590C2
Publication numberUS 3439085 A, US 3439085A, US-A-3439085, US3439085 A, US3439085A
InventorsHartmann Ludwig
Original AssigneeFreudenberg Carl Kg
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Process for the production of non-woven elastic polyurethane fabric
US 3439085 A
Abstract  available in
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Claims  available in
Description  (OCR text may contain errors)

United States Patent Int. (:1. D01f 7/56,- D06m 3/24 U.S. Cl. 264210 4 Claims This application relates to the production of filament material, and more particularly to the production of fabrics from filaments, especially non-woven fabrics.

This application is a continuation-in-part of application Ser. No. 341,489, filed Jan. 27, 1964, and the disclosure of the said co-pending application is incorporated herein by reference.

Ser. No. 341,489 discloses a process for spinning of filaments which comprises issuing a fused polymer mass in the form of filaments from several linear rows of spinneret holes of a spinneret head, and directing gas streams into impinging and entraining relation with the issuing fused polymer filaments to draw them and orient polymer molecules in the direction of the filament axis. The mass is drawn to reduce the diameter from the diameter of the spinneret hole in the ratio of at least 30:1, and the filaments are cooled to a set condition wherein the molecular orientation is retained. The filaments are maintained in drawn condition during the cooling by gas streams directed against the filaments to urge them to the drawn condition. In practical application, a multitude of linear, parallel filament rows are simultaneously drawn while keeping them in parallel arrangements within separate air channels, and the drawn and set filaments of the dilferent rows are finally collected on a screen or perforated roll for the formation of a fleece or mat.

It has now been found that the process of Ser. No. 341,489 can advantageously be utilized in the production of filaments from polyurethane. If a melt of polyurethane which is not cross linked or not completely cross linked is utilized in the process, and cross linking is permitted to occur during the drawing of the fused polymer issuing from the spinneret head, filaments, and in turn fabrics, characterized by uniformly high elasticity are obtained. Macro diisocyanate polyesters or polyethers containing glycols or diamines in an amount desirable for the intended cross linking, can be used. The moisture present in the air which is blown along the path of the fused polymer can be relied upon to cause the cross linking to occur.

Apparatus as is disclosed in Ser. No. 341,489 can be used in the practice of the instant invention. Thus, apparatus as is shown in Fig. of the drawing of the prior application can be used. Accordingly, the apparatus can include a plurality of parallel disposed nozzles, each having in excess of 100 holes of about 0.4 mm. diameter at a spacing of 2 mm., in a straight line. An air slot of 0.3 mm. width can be provided on each side of each line of spinneret holes at a spacing of 0.5 mm. from the line of holes. The nozzles can be heated to the temperature of the polyurethane melt or to the desired reaction temperature, and air heated to the same temperature can be blown through the slots to provide the desired drawing of the fused polymer. The air velocity leaving the slots is at least five times greater than the velocity of the threads issuing from the spinneret holes. The nozzles can be spaced about 60 mm. apart. At least about mm.

3,439,085 Patented Apr. 15, 1969 from the nozzles, in the direction of advance of the fused polymer, guide passageways are disposed. There is a guide passageway for each nozzle made up of a plate disposed above the plurality of filament forms and a plate disposed below the filament forms; the spacing of the plates is about 50 mm., and the passageway is 600 mm. in length (in the direction of travel of the filaments); the passageways terminate in the lateral direction about 10 mm. from the outermost filament form on each side. Air can be injected into the passageway through the plates, the air being injected from above and below the filaments. If desired, the guide passageways can be moved as is indicated in Fig. 8 of Ser. No. 341,489, in a rocking motion, to impart a corresponding movement to the filaments. The filaments can be collected on a drum or conveyor as is disclosed in Ser. No. 341,489.

If desired, filaments of different composition can be combined in a single fleece, using different nozzles for the different filament compositions. For example, a fabric could be formed of polyurethane and polyamide fibers.

The fibers when they are deposited on the collecting means wherein they are gathered into a fleece, can be in such condition that bonding of filaments occurs at filament crossing points. In this manner a bonded fleece can be obtained without the addition of binding agents. Such processing finds application where the fibers are all polyurethane polymer, and also where the fibers are mixtures of filaments of different composition, such as polyurethane and polyamide.

The invention is further described in the following examples.

Example 1 A granular polymer composition of parts of a condensation product of adipic acid ethylene glycol polyester and diphenyl methan-4,4'-diiso-cyanate, partially crosslinked with 30 parts butane-1,4-diol was melted in a wormpress at a temperature of 180 C. and supplied at a temperature of 200 C. to four spinning pumps. The spinning-pumps conveyed the melt to four spinning nozzles opening downwardly and heated to 205 0, arranged parallel to one another at a distance of 80 mm. apart. Each of the spinning-nozzles consisted of a straight line of holes of 400p. diameter, spaced apart 2 mm. so that each of the four longitudinal nozzles had a straight row of holes of 320 mm. length. An air slot was positioned on both sides of each line of holes. The slots were 3 mm. x 340 mm. length, and were spaced .5 mm. from the holes. Air heated to 205 C. with a pressure of 0.8 atmosphere gauge was supplied to the slots so that from both slots a band-shaped air-stream of about 340 mm. width issued. From the row of holes, in turn, issued a series of still melted polyurethane filaments, which at both sides were pulled forward by the band-shaped air streams, issuing with a velocity of about 5000 m./min. Therein the filaments were drawn from a cross-section of 400 to about 30;/.. Since the filaments were very viscid, and would upon touching at once stick together, turbulence formed through friction of the adjacent air-layers, had to be excluded. For this purpose, the thread group of each nozzle, together with the band-shaped air currents enveloping it was introduced into elongated guide-channels, which were spaced 20 mm. from the nozzle bore holes. The air channels had the following interior-measurements: 50 mm. plate distance, 340 mm. width, 600 mm. length. Additionally, the inner-walls of each air channel were rinsed with further cold air-streams, with the aid of two air slots of 0.3 mm. slot-height in each wall, disposed at the inlet and outlet side. The slots were at an angle of 10", so that an air rinsing impinged tangentially to the fiber flying direction. The pressure used for the rinse air was 3 atmospheres gauge on the slots. Through these measures it was possible to prevent a mutual entangling as well as touching of the individual filaments of each group. Since each individual nozzle had a channel allotted to it, the entangling of the threads of adjacent nozzles was not possible. The fleece formation took place after the filament left the air channels. The fibers and air-streams were separated with the aid of a screen through which suction was applied. The screen was mounted at a distance of 700 mm.

. from the outlet end of the air-channels. The matting of the Example 2 The apparatus of Example 1 was used, but nozzles 1 and 3 were supplied with the above-described polyurethane, and nozzles 2 and 4 were supplied with polycaprolactam. The Working conditions of the nozzle 2 and 4 were as follows: nozzle temperature 230 C., air temperature 230 C. The fleece formed contained, in the ratio 1:1, endless polyurethane and polyamide filaments, bonded together at crossing points.

Whereas in the examples, moisture in the air is relied upon to cause the cross linking which occurs during drawing of the filaments, any other known suitable means can be relied upon for providing the cross-linking conditions. In general, air at ambient conditions is suitable for the purpose.

What is claimed is:

1. Process for the production of non-woven elastic fabric, which comprises fusing a cross-linkable polyurethane mass; melt-spinning said fused mass into a multiplicity of substantially endless filaments; air-drawing said substantially endless filaments while maintaining said filaments in a hot and tacky state, whereby the molecules of said filaments are oriented in the direction of the axis of said filaments; laying said hot, tacky oriented substantially endless filaments on a supporting surface; cross-linkin-g said substantially endless filaments by means of moisture in said air; and welding said substantially endless polyurethane filaments to other such filaments by means of its tackiness, wherein said filaments become solid and non-tacky after said welding.

2. Process according to claim 1, wherein simultaneously a second polymer of different composition from said first-mentioned polymer is drawn into filaments in like manner, and the filaments of both polymers are collected together to form the fleece.

3. Process according to claim 1, wherein the filaments solidify after collection thereof in crossing relation and become bonded together at crossing points during the solidification.

4. Process according to claim 2, wherein the polyurethane filaments solidify after collection of both polymers in crossing relation and upon solidification filaments become bonded together at crossing points.

References Cited UNITED STATES PATENTS 2,810,426 10/1957 Till et al. 51-295 3,026,190 3/1962 McMahon et a1. 51-295 2,336,745 12/ 1943 Manning.

2,869,973 1/1959 Hubbard 16l--170 3,117,055 1/1964 Guandique et a1. 161170 3,154,611 10/1964 Dinber'gs 2 64176 3,158,525 11/1964 Reynolds 161-170 3,199,281 8/1965 Maerov et al 264210 2,411,660 11/1946 Manning 264176 DONALD J. ARNOLD, Primary Examiner.

US. Cl. X.R.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US2336745 *Dec 20, 1941Dec 14, 1943Fred W ManningMethod and apparatus for making unwoven and composite fabrics
US2411660 *May 22, 1943Nov 26, 1946Fred W ManningMethod of making filter cartridges, abrasive sheets, scouring pads, and the like
US2810426 *Dec 24, 1953Oct 22, 1957American Viscose CorpReticulated webs and method and apparatus for their production
US2869973 *Aug 25, 1954Jan 20, 1959Du PontSynthetic paper sheet of chemically bonded synthetic polymer fibers and process of making the same
US3026190 *Dec 2, 1958Mar 20, 1962American Viscose CorpElastomer bonded abrasives
US3117055 *Dec 15, 1959Jan 7, 1964Du PontNon-woven fabrica
US3154611 *Mar 30, 1962Oct 27, 1964Goodrich Co B FThermal cure of spandex fibers
US3158525 *Sep 26, 1960Nov 24, 1964Du PontResin coated unwoven fabric
US3199281 *Sep 27, 1961Aug 10, 1965Du PontComposite polyester yarn of differentially shrinkable continuous filaments
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3607567 *Jan 2, 1968Sep 21, 1971Fmc CorpApparatus for nonwoven fabric manufacture
US3684415 *Dec 16, 1970Aug 15, 1972Exxon Research Engineering CoMelt blown roving die
US3923587 *Mar 28, 1974Dec 2, 1975Rhone Poulenc TextileApparatus for the manufacture of continuous filament nonwoven web
US4091140 *May 10, 1976May 23, 1978Johnson & JohnsonContinuous filament nonwoven fabric and method of manufacturing the same
US4107364 *Jun 6, 1975Aug 15, 1978The Procter & Gamble CompanyPolymeric fibers
US4351683 *Oct 23, 1970Sep 28, 1982Minnesota Mining And Manufacturing CompanyBy extrusion and quenching of a thermoplastic material
US5366793 *Apr 7, 1992Nov 22, 1994Kimberly Clark CoAnisotropic nonwoven fibrous web
US6387471Apr 15, 1999May 14, 2002Kimberly-Clark Worldwide, Inc.Creep resistant composite elastic material with improved aesthetics, dimensional stability and inherent latency and method of producing same
US6547915Feb 8, 2002Apr 15, 2003Kimberly-Clark Worldwide, Inc.Creep resistant composite elastic material with improved aesthetics, dimensional stability and inherent latency and method of producing same
US6784125Jun 16, 2000Aug 31, 2004Kanebo, Ltd.Nonwoven thermoplastic elastomer fabric roll and method and apparatus for making same
US6833179May 14, 2001Dec 21, 2004Kimberly-Clark Worldwide, Inc.Targeted elastic laminate having zones of different basis weights
US6902796Dec 28, 2001Jun 7, 2005Kimberly-Clark Worldwide, Inc.Elastic strand bonded laminate
US6939334Dec 19, 2001Sep 6, 2005Kimberly-Clark Worldwide, Inc.disposable absorbent garments
US6967178Dec 26, 2002Nov 22, 2005Kimberly-Clark Worldwide, Inc.Elastic strand laminate
US6969441May 14, 2001Nov 29, 2005Kimberly-Clark Worldwide, Inc.Method and apparatus for producing laminated articles
US6978486Dec 26, 2002Dec 27, 2005Kimberly-Clark Worldwide, Inc.Garment including an elastomeric composite laminate
US7015155Jul 2, 2002Mar 21, 2006Kimberly-Clark Worldwide, Inc.Elastomeric adhesive
US7316840Jul 2, 2002Jan 8, 2008Kimberly-Clark Worldwide, Inc.Elastomeric composites and elastomeric composite laminates including reinforcement strands incorporated into an elastomeric adhesive film. The strands may vary in terms of levels of tension. Facing layers, such as nonwoven webs, can
US7316842Nov 4, 2003Jan 8, 2008Kimberly-Clark Worldwide, Inc.High-viscosity elastomeric adhesive composition
US7601657Dec 31, 2003Oct 13, 2009Kimberly-Clark Worldwide, Inc.Single sided stretch bonded laminates, and methods of making same
US7923505Nov 13, 2007Apr 12, 2011Kimberly-Clark Worldwide, Inc.Base polymer and high softening point tackifier resin; low cost elastomeric composite laminates; reduced bulk, low add on levels
US8043984Dec 14, 2004Oct 25, 2011Kimberly-Clark Worldwide, Inc.Layer array of continuous filament strands with elastic melt blown layer deposited; extensible facing layer bonded to only one side of said elastic layer; capable of being rolled for storage; diapers, sanitary napkins; low peel strength
US8182457May 14, 2001May 22, 2012Kimberly-Clark Worldwide, Inc.Garment having an apparent elastic band
US20110052878 *Aug 27, 2009Mar 3, 2011Wen-Shan LinDecorating cloth provided with the effect of stereoscopic vision
DE4407808A1 *Mar 9, 1994Sep 14, 1995Irnich Rolf Dipl MinReusable nappy pants for babies and patients
Classifications
U.S. Classification156/167, 442/409, 264/555, 442/400, 264/165, 264/103, 156/148, 264/171.1, 264/210.8, 442/328
International ClassificationD04H3/16
Cooperative ClassificationD04H3/16, D04H3/009
European ClassificationD04H3/009, D04H3/16