CA2296132A1 - Expanded extruded polymeric textile - Google Patents
Expanded extruded polymeric textile Download PDFInfo
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- CA2296132A1 CA2296132A1 CA002296132A CA2296132A CA2296132A1 CA 2296132 A1 CA2296132 A1 CA 2296132A1 CA 002296132 A CA002296132 A CA 002296132A CA 2296132 A CA2296132 A CA 2296132A CA 2296132 A1 CA2296132 A1 CA 2296132A1
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- Prior art keywords
- melt
- carrier
- foamed
- textile
- plastic layer
- 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.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
- B29C44/48—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length by gravity, e.g. casting onto, or between, moving surfaces
- B29C44/485—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length by gravity, e.g. casting onto, or between, moving surfaces the material being spread in the nip of two cooperating rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1209—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements by impregnating a preformed part, e.g. a porous lining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
- B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
A method of extruding a foamed plastic into a fabric carrier that relies on the use of dual multiple blowing agents, a dispersed blowing agent and a micro- encapsulated blowing agent. The resulting product is resilient with good compression rebound.</SD OAB>
Description
EXPANDED EXTRUDED POLYMERIC TEXTILE
FIELD OF THE INVENTION
This invention relates to the field of textiles. In particular, it relates to textiles wherein a polymeric "plastic" layer is bonded to a fabric substrate, and the plastic layer is in the form of a foamed matrix.
BACKGROUND TO THE INVENTION
In the production of plastic coated teactiles, the product has customarily been made by one of the following alternate procedures:
1) casting a molten plastic layer onto a fabric carrier;
FIELD OF THE INVENTION
This invention relates to the field of textiles. In particular, it relates to textiles wherein a polymeric "plastic" layer is bonded to a fabric substrate, and the plastic layer is in the form of a foamed matrix.
BACKGROUND TO THE INVENTION
In the production of plastic coated teactiles, the product has customarily been made by one of the following alternate procedures:
1) casting a molten plastic layer onto a fabric carrier;
2) bonding a pre-formed plastic layer onto a fabric carrier by calendering and/or use of adhesives; and
3) extruding a molten plastic layer onto a fabric carrier.
When it has been intended to provide a plastic layer that is "foamed" and resilient due to included gas-filled cells or voids, it has been customary to create the expanded plastic matrix in two stages. First a plastic layer containing a blowing agent in a quiescent state is cast on a fabric carrier. Then the formed composite textile is exposed to heat which causes gas to evolve within the plastic layer - the process of "blowing".
A disadvantage of this latter process is that the level of heat that is required to activate the blowing agent will cause carrier components in many types of fabric carriers to fuse, e.g. polyethylene will fuse at 175°F, whereas various types of chemical blowing agents require a temperature in excess of 300°F to create foaming conditions.
Attempts have been made to incorporate a blowing agent into an extruded plastic to form a foamed plastic layer. However, the use of conventional chemical blowing agents, this process produces often a textile wherein the foamed polymeric layer lacks resistance to crushing and results in a flattened polymeric layer that has almost no or little foam voids left in the structure after crushing. In a standard extrusion procedure, a chilled calendaring roll presses the extruded sheet of melt into a fabric carrier and sets, and bonds, the plastic layer with the textile.
Extruded textiles prepared with typical classic blowing agents have typically lacked the resilience to recover sufficiently from this compression step to provide a satisfactorily foamed textile.
A need exists for a foamed plastic composite textile that is formed on a permeable carrier, e.g. a woven, knitted or non-woven fabric, with a low fusing temperature, while exhibiting good recovery or resilience in response to applied pressure. This invention addresses this need as well as providing other advantages.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intends to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SLTMMARY OF THE INVENTION
According to one aspect of the invention, a method of producing a foamed sheet textile is provided:
1) extruding a polymeric melt from a linear extrusion die in the form of a sheet with two faces, the melt containing two or more classes of expanding agents:
(1) a first thermally activated gas generant dispersed within said melt; and (2) thermally expandable micro-spheres contained with encapsulating shells each containing compressed gas and being dispersed within said melt 2) allowing the expanding agents to expand, with the gas generant generating gases to form a cornpres~ble foamed matrix in the melt and allowing the micro-capsules to expand into resilient micro-spheres suspended within said foamed matrix;
3 ) depositing the melt on a permeable carrier that is in sheet form and into the surface of which the foamed melt partially penetrates; and
When it has been intended to provide a plastic layer that is "foamed" and resilient due to included gas-filled cells or voids, it has been customary to create the expanded plastic matrix in two stages. First a plastic layer containing a blowing agent in a quiescent state is cast on a fabric carrier. Then the formed composite textile is exposed to heat which causes gas to evolve within the plastic layer - the process of "blowing".
A disadvantage of this latter process is that the level of heat that is required to activate the blowing agent will cause carrier components in many types of fabric carriers to fuse, e.g. polyethylene will fuse at 175°F, whereas various types of chemical blowing agents require a temperature in excess of 300°F to create foaming conditions.
Attempts have been made to incorporate a blowing agent into an extruded plastic to form a foamed plastic layer. However, the use of conventional chemical blowing agents, this process produces often a textile wherein the foamed polymeric layer lacks resistance to crushing and results in a flattened polymeric layer that has almost no or little foam voids left in the structure after crushing. In a standard extrusion procedure, a chilled calendaring roll presses the extruded sheet of melt into a fabric carrier and sets, and bonds, the plastic layer with the textile.
Extruded textiles prepared with typical classic blowing agents have typically lacked the resilience to recover sufficiently from this compression step to provide a satisfactorily foamed textile.
A need exists for a foamed plastic composite textile that is formed on a permeable carrier, e.g. a woven, knitted or non-woven fabric, with a low fusing temperature, while exhibiting good recovery or resilience in response to applied pressure. This invention addresses this need as well as providing other advantages.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intends to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SLTMMARY OF THE INVENTION
According to one aspect of the invention, a method of producing a foamed sheet textile is provided:
1) extruding a polymeric melt from a linear extrusion die in the form of a sheet with two faces, the melt containing two or more classes of expanding agents:
(1) a first thermally activated gas generant dispersed within said melt; and (2) thermally expandable micro-spheres contained with encapsulating shells each containing compressed gas and being dispersed within said melt 2) allowing the expanding agents to expand, with the gas generant generating gases to form a cornpres~ble foamed matrix in the melt and allowing the micro-capsules to expand into resilient micro-spheres suspended within said foamed matrix;
3 ) depositing the melt on a permeable carrier that is in sheet form and into the surface of which the foamed melt partially penetrates; and
4) allowing the foamed polymeric composition so formed to set to provide a resilient compression-resistant, foamed plastic layer that is bonded to the carrier to form the resulting tactile.
Preferably, the extrusion melt, upon being laid-down on the permeable carrier, is carried on the carrier through a rotating gate defined by a gap between two rollers, one of the rollers being cooled to set the melt. This establishes a constant height for the foamed layer on the textile. The roller delivering the carrier may be powered, and the second cooled roller may be traction-driven off of the powered raller by end-rims extending from the second roller.
The resulting product of the invention is a textile having a permeable carrier into the surface of which the foamed plastic layer has expands while still molten and while the gas generants, and particularly the encapsulated expanding agent, is still expanding. Thus, the boundary surface of the carrier is at least partially embedded within the foamed plastic layer.
Expansion of the foamed layer both above and within the carrier may continue after the formed textile exits the rotating gate.
By inclusion ofthermally expandable micro-spheres in the melt the foamed plastic layer contains inclusions of thermally expanded hollow micro-spheres having encapsulating shells that are resiliently compressible. This enhances the crushability of the textile.
An advantage of this process is that polymers like PVC, polypropylene, polyethylene and other conventional polymers may be used to provide the foamed plastic layer.
Further, a textile may be produced with an integrally-formed skin region present at it's polymer surface, the skin region containing less voids than the intermediate region of the foamed layer lying between the skin region and the cawier. This is accomplished by cooling the extrusion die through which the melt is extruded.
An advantage of this process is that a textile can be produced at lower temperatures wherein the carrier would otherwise plastically deform at temperatures above, for example, 300 degrees Fahrenheit, or even 200 degrees Fahrenheit.
To produce the textile, the extruder is feed with a composition suitable for generating a foamed polymer comprising:
1) at least one expandable thermoplastic polymer capable of being extruded;
2) a first thermally activated gas generarn dispersed within said polymer, and 3 ) thermally expandable resiliently compressible micro-spheres, disbursed within said ~10 polymer, said generant and micro-spheres being capable on heating of expanding said polymer.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
SUMMARY OF THE FIGURES
Figure 1 is a schematic side view of an extrusion coating line.
Figure 2 is a cross-sectional side view of an extrusion screw.
Figure 3 is a schematic side view of the extrusion screw of Figure 2 delivering a melt of expanding polymer to the nip of a pair of rollers where the melt becomes bonded to a fabric carrier.
Figure 4 is a diag~ranunatic cross-sectional side view ofthe foamed polymeric layer bonded to a fabric carrier.
Figure 5 is a cross-sectional view through the pair of rollers receiving and combining the melt with the fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In Figures l and 2 a powdered plastic composition 2 in powder/pellet form is fed into the feed-hopper 3 of a spiral extruder screw 4. The gap around the spiraled flights 5 of the screw 4 decreases in width proceeding towards the extruder outlet 6 thus creating an increasing pressure on the melt 8 contained therein. Heat is applied externally from a heat source 7 such as hot oils, gas flames or electric radiam heating coils to convert the powdered composition 2 to a melt 8.
Preferably, the extrusion melt, upon being laid-down on the permeable carrier, is carried on the carrier through a rotating gate defined by a gap between two rollers, one of the rollers being cooled to set the melt. This establishes a constant height for the foamed layer on the textile. The roller delivering the carrier may be powered, and the second cooled roller may be traction-driven off of the powered raller by end-rims extending from the second roller.
The resulting product of the invention is a textile having a permeable carrier into the surface of which the foamed plastic layer has expands while still molten and while the gas generants, and particularly the encapsulated expanding agent, is still expanding. Thus, the boundary surface of the carrier is at least partially embedded within the foamed plastic layer.
Expansion of the foamed layer both above and within the carrier may continue after the formed textile exits the rotating gate.
By inclusion ofthermally expandable micro-spheres in the melt the foamed plastic layer contains inclusions of thermally expanded hollow micro-spheres having encapsulating shells that are resiliently compressible. This enhances the crushability of the textile.
An advantage of this process is that polymers like PVC, polypropylene, polyethylene and other conventional polymers may be used to provide the foamed plastic layer.
Further, a textile may be produced with an integrally-formed skin region present at it's polymer surface, the skin region containing less voids than the intermediate region of the foamed layer lying between the skin region and the cawier. This is accomplished by cooling the extrusion die through which the melt is extruded.
An advantage of this process is that a textile can be produced at lower temperatures wherein the carrier would otherwise plastically deform at temperatures above, for example, 300 degrees Fahrenheit, or even 200 degrees Fahrenheit.
To produce the textile, the extruder is feed with a composition suitable for generating a foamed polymer comprising:
1) at least one expandable thermoplastic polymer capable of being extruded;
2) a first thermally activated gas generarn dispersed within said polymer, and 3 ) thermally expandable resiliently compressible micro-spheres, disbursed within said ~10 polymer, said generant and micro-spheres being capable on heating of expanding said polymer.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
SUMMARY OF THE FIGURES
Figure 1 is a schematic side view of an extrusion coating line.
Figure 2 is a cross-sectional side view of an extrusion screw.
Figure 3 is a schematic side view of the extrusion screw of Figure 2 delivering a melt of expanding polymer to the nip of a pair of rollers where the melt becomes bonded to a fabric carrier.
Figure 4 is a diag~ranunatic cross-sectional side view ofthe foamed polymeric layer bonded to a fabric carrier.
Figure 5 is a cross-sectional view through the pair of rollers receiving and combining the melt with the fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In Figures l and 2 a powdered plastic composition 2 in powder/pellet form is fed into the feed-hopper 3 of a spiral extruder screw 4. The gap around the spiraled flights 5 of the screw 4 decreases in width proceeding towards the extruder outlet 6 thus creating an increasing pressure on the melt 8 contained therein. Heat is applied externally from a heat source 7 such as hot oils, gas flames or electric radiam heating coils to convert the powdered composition 2 to a melt 8.
5 Molten plastic composition or "melt" 8 passes from the extruder outlet 6 to the extrusion die 9 where the pressure that previously arrested the release of gas by the gas generants (not shown in Figure 2) is relaxed, allowing the gas generants to "blow" and produce a foamed melt 10. This foamed melt 10 is fed into the nip 15 between two counter rotating rollers 11, 12.
One of the rollers 11, preferably a powered roller 11, carries a sheet of a permeable, preferable fabric on fibrous matrix of porous, carrier material 13 from a carrier-source roller 14 to the nip 15. The other roller 12, preferably driven in a counter rotating direction by friction off of the powered roller 11, provides a gap 16 having a pre-determined diameter at the nip 15 which serves as a gate for metering the thickness of foamed melt 10 that is laid down on the carrier sheet 13. Desirably, the roller 12 has a protruding circumferential end rim 25 positioned to bear against an interface 26 between the first and second rollers 11, 12 whereby a traction drive effect occurs. Preferably, this "gating" roller 12 is temperature controlled, e.g.
chilled as by circulating chilling fluid coolant, (not shown) or other suitable method of cooling in the normal manner known for extrusion processes.
Preferably, the die 9 is also cooled, as by cooling air, to form a skin 20 surface on the foamed melt 10 as it leaves the die 9. This skin 20 has less voids than the core of the foamed layer, e.g. 50% or less.
In the gap 16 the foamed melt 10 continues its expansion, having infiltrated or mixed with the boundary surface of the carrier 13 and set therein. The composite textile 17 exits the two rollers 11, 12 and is carried by a series of conveying andJor cooling rollers 18 to a textile take-up roll 19. Some partial expansion of the foamed layer 10 may occur while the textile 19 is on the conveying rollers 18. As well, expansion within the carrier 13 may also continue.
One of the rollers 11, preferably a powered roller 11, carries a sheet of a permeable, preferable fabric on fibrous matrix of porous, carrier material 13 from a carrier-source roller 14 to the nip 15. The other roller 12, preferably driven in a counter rotating direction by friction off of the powered roller 11, provides a gap 16 having a pre-determined diameter at the nip 15 which serves as a gate for metering the thickness of foamed melt 10 that is laid down on the carrier sheet 13. Desirably, the roller 12 has a protruding circumferential end rim 25 positioned to bear against an interface 26 between the first and second rollers 11, 12 whereby a traction drive effect occurs. Preferably, this "gating" roller 12 is temperature controlled, e.g.
chilled as by circulating chilling fluid coolant, (not shown) or other suitable method of cooling in the normal manner known for extrusion processes.
Preferably, the die 9 is also cooled, as by cooling air, to form a skin 20 surface on the foamed melt 10 as it leaves the die 9. This skin 20 has less voids than the core of the foamed layer, e.g. 50% or less.
In the gap 16 the foamed melt 10 continues its expansion, having infiltrated or mixed with the boundary surface of the carrier 13 and set therein. The composite textile 17 exits the two rollers 11, 12 and is carried by a series of conveying andJor cooling rollers 18 to a textile take-up roll 19. Some partial expansion of the foamed layer 10 may occur while the textile 19 is on the conveying rollers 18. As well, expansion within the carrier 13 may also continue.
6 ' In the above process, the powdered plastic composition 2 may be a polymeric vinyl compound, a polypropylene compound, a polyethylene compound, or other known and conventional polymeric material, or combinations thereof:, for producing foamed plastic sheet textiles. In particular, the plastic composition 2 may include dual expansion agents, comprising:
1) a dispblowing agent or gas generant such as azodicarbonamide or other chemical blowing agents;
2) a micro-encapsulated expansion agent such as EXPANDCEL - TM (by Casco Nobel AB of Sweden cf U.S. patent 5,585,119) or such other encapsulated expansion agents which upon foaming provides compression-resistant micro-spheres within the plastic layer of the final textile 17; and 3) the compound may or may-not contain an additional, direct gas-injected blowing agent.
A typical composition of this invention which is eactrudable may contain one or more conventional additives such as fillers, plasticisers, stabilizers, anti-oxidants, lubricants and processing aids. Such additives can be used in conventional quantities for formulating an extrudable composition. As additives, this composition 2 may include comrentional binders, such as an acrylic and\or a nitrile rubber, ar the like, that serve to constrain and delay the expansion of the foamed melt 10.
By way of exemplification, the following table shows a typical composition which can be used in accordance with this invention. It is highly desirable that all additives and components of the composition be chlorine-free.
1) a dispblowing agent or gas generant such as azodicarbonamide or other chemical blowing agents;
2) a micro-encapsulated expansion agent such as EXPANDCEL - TM (by Casco Nobel AB of Sweden cf U.S. patent 5,585,119) or such other encapsulated expansion agents which upon foaming provides compression-resistant micro-spheres within the plastic layer of the final textile 17; and 3) the compound may or may-not contain an additional, direct gas-injected blowing agent.
A typical composition of this invention which is eactrudable may contain one or more conventional additives such as fillers, plasticisers, stabilizers, anti-oxidants, lubricants and processing aids. Such additives can be used in conventional quantities for formulating an extrudable composition. As additives, this composition 2 may include comrentional binders, such as an acrylic and\or a nitrile rubber, ar the like, that serve to constrain and delay the expansion of the foamed melt 10.
By way of exemplification, the following table shows a typical composition which can be used in accordance with this invention. It is highly desirable that all additives and components of the composition be chlorine-free.
7 TABLE
COMPOUND WEIGHT IN r~XTURE
Polymer: - PVC 136 pounds Filler: 40.7 pounds (Omyacarb) Micro-encapsulating blowing agent:1.0 pounds (Expancel 092) Dispersed blowing agent: 4.1 pounds (Celogen 754A) Plasticizer/Co-stabilizer: 102 pounds (Soy Bean Oil) Stabilizer: 3.7 pounds (Nuostabe) Anti-oxident: .3 pounds (Irganox) Lubricants: 3.3 pounds (InternaUexternal-stearic acid, "Loxiol" and Hostalub) Process Aid: 6.8 pounds (K120I~
The resulting textile 17 is thereby rendered resilient and crush resistant.
This textile may be further processed by pressure and/or vacuum-forming or injection molding without the foam layer being crushed or destroyed.
A sample textile 17 is depicted in Figure 4 wherein the foamed layer 10 is bonded to the carrier 13. Within the foamed layer 10 are two types of voids: voids 21 in the foamed matrix produced by the dispersed gas generant; and voids 22 present within expanded micro-
COMPOUND WEIGHT IN r~XTURE
Polymer: - PVC 136 pounds Filler: 40.7 pounds (Omyacarb) Micro-encapsulating blowing agent:1.0 pounds (Expancel 092) Dispersed blowing agent: 4.1 pounds (Celogen 754A) Plasticizer/Co-stabilizer: 102 pounds (Soy Bean Oil) Stabilizer: 3.7 pounds (Nuostabe) Anti-oxident: .3 pounds (Irganox) Lubricants: 3.3 pounds (InternaUexternal-stearic acid, "Loxiol" and Hostalub) Process Aid: 6.8 pounds (K120I~
The resulting textile 17 is thereby rendered resilient and crush resistant.
This textile may be further processed by pressure and/or vacuum-forming or injection molding without the foam layer being crushed or destroyed.
A sample textile 17 is depicted in Figure 4 wherein the foamed layer 10 is bonded to the carrier 13. Within the foamed layer 10 are two types of voids: voids 21 in the foamed matrix produced by the dispersed gas generant; and voids 22 present within expanded micro-
8 spheres 23. Each micro-sphere 23 has an encapsulating shell of resilient, compression resistant material. The presence of two types of voids 2l, 22 improves the character and "feel" of the final textile product 17.
CONCLUSION
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invemion in its broadest, and more specific aspects, is fiuther described and defined in the claims which now follow.
These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
CONCLUSION
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invemion in its broadest, and more specific aspects, is fiuther described and defined in the claims which now follow.
These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
Claims (23)
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of producing a foamed sheet textile comprising:
1) extruding a polymeric melt from a linear extrusion die in the form of a sheet with two faces, the melt containing two or more classes of expanding agents:
(1) a first thermally activated gas generant dispersed within said melt; and (2) thermally expandable micro-spheres having encapsulating shells each containing compressed gas and being dispersed within said melt 2) allowing the expanding agents to expand, with the gas generant generating gases to form a compressible foamed matrix in the melt and allowing the micro-spheres to expand into resilient, expanded micro-spheres suspended within said foamed matrix;
3) depositing the melt on the surface of a permeable carrier that is in sheet form whereby the foamed melt partially penetrates said surface; and 4) allowing the foamed polymeric composition so formed to set to provide a resilient compression-resistant, foamed plastic layer that is bonded to the carrier to form the resulting textile.
1) extruding a polymeric melt from a linear extrusion die in the form of a sheet with two faces, the melt containing two or more classes of expanding agents:
(1) a first thermally activated gas generant dispersed within said melt; and (2) thermally expandable micro-spheres having encapsulating shells each containing compressed gas and being dispersed within said melt 2) allowing the expanding agents to expand, with the gas generant generating gases to form a compressible foamed matrix in the melt and allowing the micro-spheres to expand into resilient, expanded micro-spheres suspended within said foamed matrix;
3) depositing the melt on the surface of a permeable carrier that is in sheet form whereby the foamed melt partially penetrates said surface; and 4) allowing the foamed polymeric composition so formed to set to provide a resilient compression-resistant, foamed plastic layer that is bonded to the carrier to form the resulting textile.
2. A method as in claim 1 in combination with cooling means for said extrusion die whereby a skin layer of partially set melt forms on the faces of the sheet as it exits the die.
3. A method as in claim 2 in combination with paired courner-rotating rollers forming a gap there between, the first of said rollers conveying the permeable carrier sheet to a contact zone at said gap for contact with the melt, the second of said rollers being cooled, wherein the melt sheet is passed into the contact zone to contact and penetrate the surface of the carrier.
4. A method as in claim 3 wherein the melt, upon coming into contact with and penetrating into the surface of the permeable carrier passes through the gap which serves as a rotating gate defined by a fixed separation between said two rollers to thereby limit the height of the melt deposited on the carrier.
5. A method as in claim 4 wherein the first roller is powered and the second roller has protruding circumferential end rims which bear upon the first roller thereby actuating the second roller by traction.
6. A method as in claim 4 wherein the melt deposited on the carrier retains sufficient temperature after passing through the gate to permit the melt to continue to expand within the carrier and to expand its height above the carrier after passing through the gate.
7. A method as in claim 1 wherein the melt comprises as its principal polymeric component a polymeric composition selected from the group of compounds consisting of polyvinyl chloride, polyethylene, and polypropylene and combinations thereof.
8. A method as in claim 7 wherein the principal polymeric component of the melt consists principally of polyvinyl chloride in combination with additives.
9. A method as in claim 7 wherein the principal polymeric component of the melt consists principally of polyethylene in combination with additives, the melt being chlorine-free.
10. A method as in claim 7 wherein the principal polymeric component of the melt consists principally of polypropylene in combination with additives, the melt being chlorine-free.
11. A foamed polymeric sheet textile having a porous carrier in the form of a sheet into which a foamed melt has expanded while still molten to provide an overlying plastic layer embedded in the boundary surface of the carrier, said foamed plastic layer containing inclusions of thermally expanded hollow micro-spheres having encapsulating shells that are resiliently compressible.
12. A textile as in claim 11 wherein the foamed plastic layer comprises as its principal a polymeric component, a composition selected from the group of compounds consisting of polyvinyl chloride, polyethylene, and polypropylene and thermoplastic urethane and combinations thereof.
13. A textile as in claim 12 wherein the polymeric component of the foamed plastic layer consists principally of polyvinyl chloride in combination with additives.
14. A textile as in claim 12 wherein the polymeric component of the foamed plastic layer consists principally of polyethylene in combination with additives which are chlorine-free.
15. A textile as in claim 12 wherein the foamed plastic layer consists principally of polypropylene in combination with additives which are chlorine-free.
16. A textile as in claims 11, 12, 13, 14 or 15 wherein said foamed plastic layer has a surface opposite said carrier with an integrally-formed skin region present at said surface, the skin region containing less voids than the intermediate region of the foamed layer lying between the skin region and the carrier.
17. A textile as in claim 16 wherein the percentage of voids in the skin region is less than 50%
of the percentage of voids in the intermediate region.
of the percentage of voids in the intermediate region.
18. A textile as in claim 16 wherein said carrier is a fibrous matrix.
19. A textile as in claims 11, 16, 17 or 18 wherein said carrier plastically deforms at temperatures above 300 degrees Fahrenheit.
20. A textile as in claim 19 wherein said carrier plastically deforms at temperatures above 200 degrees Fahrenheit.
21. A composition suitable for generating a foamed polymer comprising:
1) at least one expandable thermoplastic polymer capable of being extruded;
2) a first thermally activated gas generant dispersed within said polymer; and 3) thermally expandable resiliently compressible micro-spheres, disbursed within said polymer;
said generant and micro-spheres being capable on heating of expanding said polymer.
1) at least one expandable thermoplastic polymer capable of being extruded;
2) a first thermally activated gas generant dispersed within said polymer; and 3) thermally expandable resiliently compressible micro-spheres, disbursed within said polymer;
said generant and micro-spheres being capable on heating of expanding said polymer.
22. A composition as defined in Claim 21 further comprising:
at least one additive chosen from fillers, plasticisers, stabilizers, anti-oxidants, processing aids and lubricants.
at least one additive chosen from fillers, plasticisers, stabilizers, anti-oxidants, processing aids and lubricants.
23. A composition as defined in Claim 21 wherein the polymer is a polypropylene, polyethylene or polyvinyl chloride polymer or copolymer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002296132A CA2296132A1 (en) | 1999-12-24 | 2000-01-14 | Expanded extruded polymeric textile |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2293147 | 1999-12-24 | ||
| CA2,293,147 | 1999-12-24 | ||
| CA002296132A CA2296132A1 (en) | 1999-12-24 | 2000-01-14 | Expanded extruded polymeric textile |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2296132A1 true CA2296132A1 (en) | 2001-06-24 |
Family
ID=25681429
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002296132A Abandoned CA2296132A1 (en) | 1999-12-24 | 2000-01-14 | Expanded extruded polymeric textile |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2296132A1 (en) |
-
2000
- 2000-01-14 CA CA002296132A patent/CA2296132A1/en not_active Abandoned
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