EP0043390B1 - Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe - Google Patents

Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe Download PDF

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Publication number
EP0043390B1
EP0043390B1 EP19800302182 EP80302182A EP0043390B1 EP 0043390 B1 EP0043390 B1 EP 0043390B1 EP 19800302182 EP19800302182 EP 19800302182 EP 80302182 A EP80302182 A EP 80302182A EP 0043390 B1 EP0043390 B1 EP 0043390B1
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EP
European Patent Office
Prior art keywords
web
composite sheet
sheet structure
filaments
net
Prior art date
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Expired
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EP19800302182
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English (en)
French (fr)
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EP0043390A1 (de
Inventor
Yasuyuki Yamazaki
Shingo Emi
Susumu Noroto
Tomoyoshi Ono
Kazuo Takamatu
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Teijin Ltd
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Teijin Ltd
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Priority to DE8080302182T priority Critical patent/DE3069016D1/de
Priority to EP19800302182 priority patent/EP0043390B1/de
Publication of EP0043390A1 publication Critical patent/EP0043390A1/de
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Publication of EP0043390B1 publication Critical patent/EP0043390B1/de
Expired legal-status Critical Current

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Classifications

    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • 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
    • D04H13/00—Other non-woven fabrics
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments

Definitions

  • This invention relates to an improved composite sheet structure having various superior properties, especially high flexibility, excellent nap resistance, good air permeability, high strength, good heat sealability and light weight.
  • a great number of methods are known for producing a nonwoven web composed of continuous filaments of a synthetic resin in which the individual filaments are arranged at random, such as a spun- bond method and a fiber-opening or -spreading method.
  • Many techniques are also known for giving practical interfilament bonding to such a nonwoven web. They include, for example, the use of a binder, physical intertwining means such as needling using a needle or fluid, and heat bonding utilizing the melt-bondability of filaments, either singly or in combination.
  • High flexibility is generally incompatible with excellent nap resistance or with high strength, and good air permeability is likewise generally incompatible with superior nap resistance. It has been impossible in practice to provide a well-balanced combination of desirable properties, for example high flexibility, excellent nap resistance, good air permeability and high strength.
  • JP-A-49284/77 published April 20, 1977 suggested a structure comprising a nonwoven web (A) composed of (a) continuous filaments of synthetic thermoplastic resin and a net-like web (B) having intersecting points and composed of (b) continuous net strands of thermoplastic sythetic resin composed of a mixture of at least two resins having different melting points, said webs (A) and (B) being bonded to each other by heating.
  • the nonwoven composite sheet structure is produced by extruding a thermoplastic resin mixture composed of at least two resins having different melting points such as polyethylene (m.p. 100-135°C) and polypropylene (m.p.
  • such a web (A) and web (B) can be melt-bonded so that the resulting composite sheet structure has sufficient strength.
  • the flexibility of the composite sheet structure is drastically reduced, and moreover, the sheet structure has poor air permeability.
  • the invention accordingly provides a composite sheet structure having a unique characteristic three-dimensional structure (relative structure in the thickness direction and planar directions of the sheet structure) comprising a nonwoven web (A) comprising (a) continous filaments of a synthetic resin and at least one outermost net-like web (B) wherein strands of the web intersect, said net-like web (B) being composed of (b) continuous net strands of a mixture consisting of at least two thermoplastic synthetic resins having different melting points, said nonwoven web (A) and said net-like web (B) having been bonded to each other by heating; wherein
  • This composite sheet structure has high flexibility, excellent nap resistance, good air permeability, high strength, good heat sealability and light weight which combination of properties has not been provided by the prior art.
  • the composite sheet structure of the invention can find application in a wide range of industrial, agricultural, and household fields, for example as packaging materials, apparels, interior finishing or decorating materials.
  • the composite sheet structure of this invention can be prepared by a process which comprises stacking alternate layers of said webs (A) and (B) to provide a stacked assembly in which at least one outermost layer is provided by a web (B),-and heat-treating the stacked assembly to bond the webs together.
  • the webs (A) and (B) may each be of a multilayer structure composed of two or more adjacent web layers.
  • the individual filaments (a) constituting the nonwoven web (A) are not bonded, or partly bonded, to each other. Even when they are bonded, the web (A) is preferably a web of a loose structure as a whole with the filaments being partly bonded by such means as treatment with a binder, physical intertwining, or bonding utilizing the adhesive strength of the filaments (a) themselves. In other words, the web (A) is preferably a nonwoven web which can be easily deformed by an external stress with the individual filaments (A) constituting the web being not bonded to each other, or only partly bonded loosely.
  • the web (A) preferably has a looseness, defined hereinbelow, of 0.05 to 5.0
  • the looseness is a measure of the loose structure of the web (A) and is measured in the following manner.
  • a sample, 5 cm x 20 cm, is prepared, and measured at a tensile speed of 30 cm/min. with a chuck distance being kept at 10 cm by the testing method for tensile strength described in JIS L-1085.
  • the stress (g/5 cm) at 30% stretch based on the original length of the sample is measured, and divided by the weight of the web (A) sample per unit area (g/m 2 ). The quotient is defined as the looseness of the web (A).
  • Crimped filaments are suitable as the filaments (A) for providing a nonwoven web (A) of such a loose structure.
  • such crimped filaments have a number of crimps of 10 to 40 per 2.54 cm (inch) of the filaments.
  • the filaments (A) preferably have a size of, for example, 0,011 to 1,67 tex (0.1 to 15 denier).
  • the nonwoven web (A) should meet the requirement (i), i.e. should have a basis weight of 2 to 30 g/m 2 , preferably 3 to 20 g/m 2 , as a parameter taken in combination with the other requirements. If the basis weight of the web (A) exceeds the upper limit, its bondability with the continuous net strands constituting the web (B) and meeting the requirement (ii) is reduced, and delamination tends to occur. If the basis weight of the web (A) is below the specified lower limit, the strength of the resulting composite sheet structure is difficult to retain satisfactorily.
  • the filaments (a) are distributed uniformly in the web (A).
  • the web (A) may contain other filaments, for example regenerated filaments such as rayon filaments, semi-synthetic filaments such as acetate filaments, inorganic filaments such as carbon filaments, and natural filaments such as silk.
  • the amount of the other filaments is preferably 1 to 30% by weight based on the web (A).
  • nonwoven web (A) composed of the continuous filaments of synthetic resin
  • any method of production can be employed which can afford a web having the aforesaid loose structure.
  • JP-B-27599/67 discloses a method for producing a fibrous molded article composed of continuous filaments, which comprises extruding a polymeric substance, as a melt or solution, through a number of adjoining orifices to form continuous filaments, withdrawing the continuous filaments from a spinneret and stretching and solidifying them by using an undisturbed gas or vapor stream blown against the filaments substantially parallel to both side surfaces of the filament band, simultaneously transferring the entire filament band through an air conduit in the form of a an open-ended flat box having a slightly larger width than the filament band as a wide band as-withdrawn from the spinneret without the filaments being gathered together as a yarn, and accumulating the filament band on a collecting mold moving at a lower speed than the spinning speed after it has left the conduit, whereby the filaments are entangled into a layer.
  • Another example is a process for producing filamentary structure which comprises running a multifilament yarn of continuous organic synthetic filaments, electrostatically charging the yarn to separate the filaments at the charged portion, and then gathering the filaments as-separated, as shown in JP-B-4993/62.
  • JP-B-6795/76 discloses a method for producing a nonwoven fabric which comprises separating a crimped tow so that the individual filaments are aligned substantially in one direction, provisionally bonding the filaments to each other by a small amount of an adhesive to form a fibrous sheet, extending said fibrous sheet or a plurality of such fibrous sheets in a stacked conditions in the widthwise direction, and treating the extended sheet structure with an adhesive or heat-melting the filaments to fix a network structure.
  • JP-B-6595/76 which comprises separating a crimped tow, pre-bonding the individual filaments, and extending the fibrous sheet in the widthwise directions.
  • a preferred method for separating a crimped tow is the method for producing a sheet-like material which comprises feeding continuous multifilaments between a pair of rotating intermeshing gear-like rollers at a speed slower than the surface speed of the rollers to bend the multifilaments, relaxing the filaments to deposite them in sheet form, and then fixing the relative positions of the single filaments, which is disclosed in JP-B-6114/71.
  • the net-like web (B) must meet requirement (ii) set out above as a parameter taken in conjunction with the other requirements.
  • This requirement (ii) is an important factor for the composite sheet structure of this invention to meet the structural requirements (v) in conjunction with the requirements (i), (iii) and (iv).
  • the net strands (b) constituting the net-like web (B) are composed of a blend of at least two resins having melting points differing from each other by at least 20°C, for example by 20 to 200°C.
  • the one having the lowest melting point has a melting point at least 20°C, for example 20 to 200°C, lower than the melting point of the resin constituting the filaments (a).
  • the amount of the resin having the lowest melting point is 5 to 95% by weight, preferably 10 to 90% by weight, based on the weight of the resin blend.
  • a composite sheet structure having the requirement (v) can be surely formed without likelihood of a substantial loss of the loose structure by which the web (A) of the composite sheet structure can be easily deformed by an external stress. If, however, the difference between the melting points of the two resins constituting the resin mixture is less than 20°C, and/or the amount of the resin having the lowest melting point is outside the above-specified range, it is impossible in practice to form a sheet structure having the requirement (v), and a composite sheet structure having the properties of a composite sheet structure of this invention cannot be obtained.
  • the web (B) used in this invention has a basis weight of 1 to 10 g/m 2 , preferably 2 to 8 g/m 2 , an average net strand diameter of 1 to 100 ⁇ m, preferably 2 to 80,um, and an average mesh length of up to 5 mm, preferably 0.1 to 4 mm.
  • the basis weight of the web (B) exceeds the above-specified upper limit, the flexibility of the composite sheet structure is reduced. If it is less than the specified limit, it is difficult to avoid the formation of fuzzes. If the average net strand diameter is larger than the above-specified limit, the flexibility of the sheet structure is reduced. If it is smaller than the specified limit, its air permeability is reduced. On the other hand, use of a net-like web having an average mesh length of more than 5 mm leads to a sheet structure having poor nap resistance and poor heat sealability.
  • a web (B) having the basis weight, average net strand diameter and average mesh length specified in requirement (ii) above preferably is such that when a straight line connecting two arbitrary points spaced from each other by a distance of 2 mm is drawn at an arbitrary part of the surface of the web (B), 3 to 100, particularly 6 to 30, net strands (b) cross this straiaht line.
  • any method can be used which can afford a net-like web meeting the requirement (ii).
  • a method which comprises forming numerous irregular crackings in a thin film, and then extending the film, and (ii) a method which comprises rotating a two-layer ring die having numerous fine nozzles arranged annularly, and extruding a fibrous substance through these nozzles to form a net-like sheet continuously.
  • JP-B-3458/74 is a method for producing an opened web which comprises extruding a molten thermoplastic resin containing a blowing agent from a die, pulling the extrudate to form a sheet-like structure having numerous non-continuous cracks in one direction, laminating a plurality of such sheet-like structures so that the directions of the cracks coincide, feeding the resulting laminate through stuffing rollers and inlet rollers in the relaxed state so that the ratio of the feed rate of the stuffing rollers to the feed rate of the inlet rollers is 1.1-3.0:1, and spreading the individual fibers of the laminate at a spreading angle of 10 to 60 degrees and a spreading ratio of 3 to 15.
  • the web (B) in this invention has intersecting points and is composed of continuous net strands.
  • a net-like web of the type produced by the method disclosed in JP-A-3458/74 is an assembly of continuous multifilaments in which the individual net strands are connected to each other at random and spaced from each other at irregular intervals to form a number of mesh openings which' differ from each other randomly and irregularly in shape and size.
  • the aforesaid points of connection form intersecting points as branching points of the net strands.
  • the amount of the web (A) in the composite sheet structure of this invention is 30 to 90% by weight, preferably 40 to 80% by weight, based on the total weight of the webs (A) and (B).
  • This requirement (iii) is an essential parameter in combination with other requirements.
  • the weight ratio of the web (A) to web (B) per unit area in the composite sheet structure of this invention is (30-90); (70-10), preferably (40-80); (60-20). If in the composite sheet structure of this invention, the proportion of the web (A) is larger than the above specified upper-limit, the nap resistance and heat sealability of the resulting composite sheet structure are degraded.
  • the proportion of the web (A) is smaller than the above-specified lower limit, the flexibility or air permeability of the resulting composite sheet structure are degraded.
  • the proportion of the web (a) increases within the above range, the flexibility or air permeability of the sheet structure tends to be' improved.
  • the proportion of the web (B) increases, the nap resistance of the sheet structure tends to increase.
  • the suitable ratio of the web (A) to the web (B) can be selected within the above range depending upon the desired balance of the aforesaid properties.
  • the composite sheet structure of this invention should have a basis weight of 10 to 200 g/m 2 , preferably 12 to 150 g/m 2 , [requirement (iv)]. If the basis weight of the sheet structure of this invention is larger than the above-specified upper limit, the flexibility and air permeability of the sheet structure are degraded. If on the other hand, its basis weight is smaller than the specified lower limit, the strength of the structure is too low to be practical.
  • the composite sheet structure of the present invention has a unique characteristic three-dimensional structure in the thickness direction and the planar direction (longitudinal and transverse directions). Specifically, in the composite sheet structure, the filaments (a) are embraced by the net strands (b) partly at many points throughout the composite sheet structure [requirement (v)], in addition to meeting the other requirements (i), (ii), (iii) and (iv).
  • This embracing structure is a structure in which webs (A) and (B) are integrated to such an extent as to permit a loose structure for the entire web (A) in which the filaments (a) not bonded or loosely bonded of the nonwoven web (A) capable of easily deforming by an external stress can be displaced with respect to each other relatively easily.
  • This structure includes, for example, a structure in which the resin having the lowest melting point in the resin mixture constituting the net strands (b) of the web (B) is melt-bonded with the filament or filaments (a) of the web (A) partly at many points, or completely or incompletely occludes the filament or filaments (a) partly at many points; or a structure in which the resin having the lowest melting point in the filaments (b) completely or incompletely bridges a plurality of layers of the web (B) having the web (A) interposed therebetween in the thickness direction of the composite sheet structure either perpendicularly or obliquely with or without the occluding structure mentioned above.
  • the non-woven filaments (a) in the web (A) are partly embraced by the net strands (b) of the web (B) throughout the composite sheet structure without a loss of displaceability of these filaments to each other.
  • the web (B) is a net-like web having intersecting points and is composed of continuous net strands
  • the composite sheet structure of this invention meeting the aforesaid requirements (i) to (v) becomes a unique composite sheet structure having improved properties which cannot stand together in conventional composite sheet structures.
  • the accompanying drawings are optical microphotographs of one embodiment of the composite sheet structure of this invention composed of 5 layers of the web (B) and 4 layers of the web (A) which are obtained by stacking them in the order of web (B)-web (A)-web (B)-web (A)-web (B)-web (A)-web (B)-web (A)-web (B) and bonding them by heat treatment (300 X in the. case of a cross section, and 100 X in the case of a surface).
  • Figure 1 is a top plan view of the above structure before the heat-treatment; and Figures 2-1 and 2-2 are partial sectional views of the aforesaid embracing structure of the composite sheet structure of this invention after the heat-treatment.
  • Figure 1 well shows the net-like web (B) overlaid on the web (A).
  • This Figure shows the structure obtained in Example 1 given hereinbelow.
  • the filaments (a) of the webs (A) are bridged at many points of the composite sheet structure by the net strands (b) of the webs (B) aligned alternately with the webs (A), and are thus partly embraced throughout the composite sheet structure.
  • the three-dimensional structure of the composite sheet structure of this invention attributed to the embracing structure of requirement (v) serves to integrate the web (A) and the web (B) without causing a loss of the loose structure of the web (A) and to impart a well-balanced combination of improved properties such as high flexibility, excellent nap resistance, good air permeability and high strength to the composite sheet structure thus obtained.
  • the resins for production of the webs (A) and (B) forming constituting the composite sheet structure of this invention can be selected from various combinations of resins which meet the requirement (ii).
  • examples of usable resins include (1) homopolymers or copolymers of ethylene, propylene, styrene, acrylic esters, vinyl acetate, acrylonitrile, vinyl chloride, etc.; (2) polyesters prepared from at least one dicarboxylic acid component (or a lower alkyl ester thereof) selected from of aromatic dicarboxylic acids having 8 to 15 carbon atoms such as phthalic acids (e.g., phthalic acid, isophthalic acid, terephthalic acid, the nuclearly alkylated derivatives thereof) or naphthalenedicarboxylic acids, aliphatic dicarboxylic acids having 6 to 30 carbon atoms and alicyclic dicarboxylic acids having 6 to 30 carbon atoms and at least one glycol component selected from the group consisting of aliphatic
  • the filaments (a) constituting the web (A) are base filaments which maintain the strength of the entire composite sheet structure, and preferably composed of a resin having a relatively high melting point.
  • the filaments (a) are selected from those of a resin selected from polyethylene terephthalate, polybutylene terephthalate, polycapramide, poly-m-phenyl isophthalamide, polypropylene and polyacrylonitrile, and mixtures or copolymers thereof. They are preferably stretched and oriented.
  • the strands (b) constituting the web (B) are preferably prepared from resins meeting the melting point requirement in (ii).
  • resins are polyesters such as polyethylene terephthalate and polybutylene terephthalate; polyamides such as polycapramide and polyhexamethylene adipamide; polyolefins such as polyethylene and polypropylene; vinyl polymers such as polyvinyl alcohol, polyvinyl acetate and polyacrylonitrile; polyurethanes; and copolymers of these. More preferably, these resins have a melting point of from 100 to 300°C.
  • the heat treatment whereby the webs (A) and (B) are bonded to each other in the embracing structure can be performed, for example, by passing the stacked sheet-like assembly of webs (A) and (B) between one pair, or a plurality of pairs, of hot press rollers.
  • these press rollers has a flat surface.
  • the heat-treatment is carried out preferably at a temperature X (°C) defined by the following equations [I] and [II], and more preferably by equation [I]'.
  • T,, T 2' T 3 , ... T " are the melting points (decomposition points when no melting point is shown) of the resins having melting points differing from each other by at least 20°C in the resin mixture constituting the net strands (b); W,, W 2 , W3, ... W n represent the proportions in weight percentage of these resins in the resin mixture; and T (a) is the melting point (decomposition point when no melting point is shown) of the resin which constitutes the filaments (a).
  • the heat treatment be carried out at a temperature which is at least 30°C lower than the melting point of the filaments (a) but not more than a temperature which is 30°C lower than the melting point of a resin having the lowest melting point among the resins in the resin mixture constituting the web (B).
  • the composite sheet structure of this invention is composed of a high-melting component and a low-melting component and can be easily formed into a bag having a firm sealed portion by a well-known method such as heat sealing or high-frequency sealing, it is useful as a packaging material having flexibility, high strength, good air permeability and reduced nap.
  • a polymer component having good weatherability the sheet structure of this invention is also useful as an agricultural material having reduced nap, high flexibility and good air permeability.
  • the composite sheet structure of this invention finds wide applications as general industrial materials, household goods, sanitary materials and apparel materials.
  • the composite sheet structure of this invention may further contain suitable additives for the purpose of improving or imparting coloration, electrical properties, chemical properties, physical properties, and other properties.
  • suitable additives are pigments, antistatic agents, fire retardants, plasticizers, antioxidants, stabilizers, ultraviolet absorbers, lubricants, oiling agents, and perfumes.
  • a laminate By laminating two or more layers of the composite sheet structure, a laminate can be obtained. Lamination in this case is carried out, for example, by a bonding means using a binder, a physical bonding means such as needle punching, a sewing means using a sewing machine, or hot pressing. In making the laminate, the composite sheet structures may be bonded at their entire surfaces, or only partly.
  • the composite sheet structure of the invention may also be laminated to another sheet material such as woven or knitted cloth, a nonwoven cloth, paper, a glass mat, a film, a foamed sheet, a corrugated paperboard, or a metallic meshwork.
  • another sheet material such as woven or knitted cloth, a nonwoven cloth, paper, a glass mat, a film, a foamed sheet, a corrugated paperboard, or a metallic meshwork.
  • the average net strand diameter in the web (B), the average mesh length of the web (B), the fiber density of the web (B), and the various properties of the composite sheet structure are determined by the following methods.
  • a straight line is drawn on the microphotograph obtained in (1) above at an arbitrary angle to the net strand (b) and the diameter (d ; ) of the net strand at the intersecting point is measured (at 100 points).
  • the quotient (d in ⁇ m) obtained by dividing d, by the number (n) of measurings is defined as the average diameter of the net strand.
  • the strength of the composite sheet structure is expressed by the quotient obtained by dividing the tensile strength (g/5 cm) by the weight of the sheet structure per unit area (g/m 2 ).
  • the composite sheet structure of this invention has a strength of 100 to 400
  • the tensile test described in JIS L-1085 is conducted, and from the resulting load-elongation curve, the initial Young's modulus is calculated in accordance with the equation described in Paragraphs 5 to 10, Remark 2 of JIS L-1074. As the specific gravity used in this equation, the apparent bulk density (g/cm 3 ) is used.
  • the composite sheet structure of this invention has an initial Young's modulus of 4.9 to 390 MP 2 (0.5 to 40 kg/mm 2 ) (an average of the measured values obtained in the longitudinal and transverse directions).
  • the composite sheet structure of this invention preferably has a stiffness of 0.5 to 8
  • Air permeability can be determined by passing air at a predetermined flow rate through the composite sheet structure of a predetermined area, and measuring the difference in pressure on both sides of the structure.
  • the composite sheet structure is placed at right angles to a vinyl chloride resin cylinder having an inside diameter of 60 mm at a position intermediate in the cylinder. From one end of the cylinder, air is caused to flow at a rate of 3 m/sec. through a rectifying plate, and the difference in pressure between both sides of the structure is measured by a manometer. As a result, the air resistance (mmAq.) at the time of passing air at 3 m/sec. through the structure with a cross-sectional area of 28.3 cm 2 can be determined. The quotient obtained by dividing the air resistance (mmAq.) by the weight of the structure per unit area (g/m 2 ) is defined as air permeability
  • the surface of the composite sheet structure is rubbed under certain conditions, and the state of napping is observed.
  • the sheet structure of this invention has a nap resistance of 25 to 200 times.
  • Polyethylene terephthalate filaments having a monofilament denier size of 6 denier were aligned substantially parallel to each other so that the total denier size of these filaments was 1,300,000 denier. They were stretched to 4 times, crimped at a rate of 18/2.54 cm (inch), and heat-set at 180°C for 2 minutes. The resulting product was again stretched to form a sheet. The sheet was fed between a pair of intermeshingly rotating gear-like rollers at a speed slower than the surface speed of the rollers to spread it continuously, and extended to a width of 1.5 m by an arcuate bar.
  • the product was entirely impregnated with an emulsion-type adhesive obtained by adding a small amount of an emulsifier to an ethyl acrylate/butylacrylate (50:50 by weight) so that the pick-up was 4% by weight.
  • the impregnated product was dried at 100°C to form a sheet having a basis weight of 30 g/m 2 and composed of parallel filaments.
  • the sheet obtained was extended to 13.5 times in the widthwise direction by a pin tenter while feel - it at an overfeed of 1.8 times to obtain a nonwoven random web (A) having a monofilament of 0.17 tex (1.5 denier) and a basis weight of 4 g/m 2.
  • the sheet (B) had an average monofilament diameter of 40,um and a basis weight of 1.7 g/m 2 , and the individual fibers were continuous and formed a network structure.
  • the temperature X(°C) suitable for heat-treating this laminate was determined from equations [I]' and [II] as 189 ⁇ X ⁇ 139 because the polyethylene terephthalate had a melting point of 260°C, polypropylene had a melting point of 160°C, nylon 6 had a melting point of 225°C, and polyethylene had a melting point of 110°C.
  • the laminated structure was pressed by a pair of hot press rollers having a flat surface and kept at a surface temperature of 160°C to form a nonwoven cloth having a basis weight of 41.6 g/m 2 in which the weight ratio of the webs (A) to the webs (B) was 67:33.
  • the product was observed by an electron microscope. It was found that the surface layer of web (B) had a mesh size of 1.04 mm on an average, a fiber density of 19 on an average, and a fiber diameter of 40,um on an average, and that some of the filaments of the web (A) were embraced by the fibers of the webs (B).
  • the properties of the resulting nonwoven cloth were determined by the methods described hereinabove. It was found to have excellent quality with reduced nap, high flexibility, high strength and good air permeability.
  • a nonwoven cloth was produced in the same way as in Example 1 except that 3 layers of the web (A) and 4 layers of the sheet (B) were laminated. Two layers of the resulting nonwoven cloth were laminated, and heat-sealed at 200°C. The two layers could be bonded to each other very firmly.
  • Example 1 The procedure of Example 1 was repeated except that the sheet (B) was produced from a mixture of 70% by weight of polyethylene terephthalate and 30% by weight of polypropylene and 0.5 part of Tinuvin 327 (a trademark for an ultraviolet absorber made by Ciba-Geigy), both the web (A) and the sheet (B) were extended to 10 times at an overfeed of 1.5 times, and the composite structure composed of the webs (A) and the sheets (B) was hot-pressed at a temperature of 200°C.
  • Tinuvin 327 a trademark for an ultraviolet absorber made by Ciba-Geigy
  • the resulting nonwoven cloth had reduced nap, high strength and good air permeability, and could retain these properties for a long period of time in outdoor use as an agricultural protective sheet.
  • Polyacrylonitrile filaments having a monofilament size of 0,19 tex (1.7 denier) were aligned substantially parallel to each other so that the total size of the filaments was 17,000 tex (150,000 denier), crimped at a rate of 20/2.54 cm (inch), and continuously spread to stretch it in the widthwise direction.
  • the resulting sheet was impregnated to a pickup of 8% with a solution (concentration 20%) of polyurethane/acrylonitrile-butadiene copolymer (weight ratio 80/20) in a mixture of butyl acetate and dimethylformamide (4:1 by weight), and then dried.
  • the sheet was then stretched to 9 times at an overfeed of 2 times to afford a web (A) having a basis weight of 4.9 g/m 2 .
  • Example 1 Seven layers of the resulting web (A) and 8 layers of the sheet (B) obtained in Example 1 were stacked alternately to obtain a laminated assembly in which both outermost layers were composed of the sheet (B). The assembly was pressed by a pair of hot press rollers having a flat surface and kept at a surface temperature of 160°C to afford a nonwoven cloth having a basis weight of 48 g/m 2 , good flexibility and reduced nap.
  • a decorative design was printed on the resulting nonwoven cloth, and a bed cover having high strength, good flexibility and reduced napping was made from it.
  • Oriented nylon-6 filaments having a monofilament size of 0.13 tex (1.2 denier) were aligned substantially parallel to each other so that the total size of the filaments was 22,000 tex (200,000 denier). These filaments were crimped at a rate of 18/2.54 cm (inch), and treated in the same way as in Example 1 to afford a nonwoven web (A) having a basis weight of 11 g/m 2 .
  • a mixture of 80% by weight of polypropylene, 10% by weight of nylon-6 and 10% by weight of polyethylene was treated in the same way as in Example 1 to afford a reticulated continuous fiber sheet (B) having a basis weight of 2.5 g/m 2 .
  • the resulting nonwoven fabric was observed by a microscope. It was found that the sheet (B) had a mesh size of 0.93 mm on an average, a fiber density of 22 on an average, and a fiber diameter of 33 ⁇ m on an average, and that some of the filaments in the web (A) were embraced by the fibers of the sheets (B).
  • the resulting nonwoven fabric had the properties within the ranges of this invention.
  • Example 2 Eight layers of the web (A) obtained in Example 1 were stacked, and pressed by a pair of hot press rollers having a flat surface and kept at a surface temperature of 200°C.
  • An emulsion-type adhesive obtained by emulsifying a copolymer of butyl acrylate and methacrylate (50/50) with a small amount of an emulsifier, and impregnated in the resulting laminate to a pick-up of 20% by weight.
  • the impregnated laminate was dried to afford an adhesive-bonded nonwoven fabric having a basis weight of 38.4 g/m 2 .
  • the fabric was liable to develop fuzzes.
  • Example 1 Six layers of the web (A) obtained in Example 1 were stacked, and a web having a basis weight of 10 g/m 2 obtained by card forming of polypropylene staples having a cut length of 2 cm and a single fiber size of 0.2 tex (2 denier) was laminated to both surfaces of the laminated structure.
  • the laminated assembly was bonded into a unitary structure by needle punching, and then hot-pressed under the same conditions as in Example 1.
  • the properties of the resulting non-woven fabric were measured by the methods described hereinabove. Great variations were noted in the flexibility, air permeability and nap resistance of the resulting nonwoven fabric.
  • Example 1 was repeated except that the cooling conditions after extrusion in the production of the sheet (B) were changed to provide a sheet (B) having a thick fiber diameter and a coarse mesh size.
  • the resulting structure was examined by an electron microscope.
  • the mesh size of the surface layer of the sheet (B) was 11 mm on an average, and the fiber diameter was 160 u .m on an average.
  • the resulting structure had harder tactile hand and was more liable to develop nap than the sheet structure obtained in Example 1.
  • a sheet (B) having a basis weight of 2.1 g/m 2 was produced from nylon-6 alone by the same method as in Example 1. Layers of the sheet (B) were laminated in combination with the layers of the web (A) obtained in Example 1 and pressed at a temperature of 200°C. The resulting structure was liable to develop naps.
  • Stretched split yarns made from polyethylene were laminated so that those yarns aligned longitudinally crossed at right angles to those aligned transversely. They were hot-pressed at 100°C to form a split yarn sheet (A) having a basis weight of 25.6 g/m 2 .
  • a sheet (B) was produced in the same way as in Example 1 except that the sheet (B) was produced from a mixture of 50% by weight of polyethylene and 50% by weight of polypropylene.
  • Table 1 summarizes the properties of the products obtained in the above Examples and Comparative Examples.

Landscapes

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

Claims (7)

1. Zusammengesetzte Schichtstruktur aus einem Vliesstoff (A) umfassend a) endlose Fäden aus einem synthetischen Harz und zumindest einer äußersten netzartigen Schicht (B), wobei sich Stränge des Netzes kreuzen und wobei die netzartige Schicht (B) zusammengesetzt ist aus b) endlossen Strängen aus einem Gemisch, bestehend aus zumindest 2 thermoplastischen synthetischen Harzen mit unterschiedlichen Schmelzpunkten und die Vliesstoffschicht (A) und die netzartige Schicht (B) durch Erhitzen miteinander verbunden sind; wobei
(i) die Vliesstoffschicht (A) ein Grundgewicht von 2 bis 30 g/m2 besitz,
(ii) die netzartige Schicht (B) ein Grudgewicht von 1 bis 10 g/m2, einen mittleren Durchmesser der Stränge von 1 bis 100 µm und eine mittlere Maschengröße (Länge) von bis zu 5 mm besitzt und die Stränge b) bestehen zus einem Gemisch aus zumindest 2 Harzen mit Schmelpunkten, die sich voneinander um mindestens 20°C unterscheiden, und das Harz mit dem niedrigsten Schmelzpunkt (I) einen Schmelzpunkt besitzt, der zumindest 20°C niedriger liegt als derjenige, der Fäden a), und (II) in einer Menge von 5 bis 95 Gew.-%, bezogen auf das Harzgemisch vorhanden ist,
(iii) die Menge an der Vliesstoffschicht (A) 30 bis 90 Gew.-% der Schichten (A) und (B) ausmacht,
(iv) die zusammengesetzte Schichtstruktur ein Grundgewicht von 10 bis 200 g/mz besitzt und
(v) die Fäden a) teilweise umfangen sind von den Strängen b) des Netzes innerhalb der zusammengesetzten Schichtstruktur.
2. Zusammengesetzte Schichtstruktur nach Anspruch 1, wobei die Fäden a) 0,011 bis 1,67 tex (0,1 bis 15 denier) stark sind.
3. Zusammengesetzte Schichtstruktur nach Anspruch 1 oder 2, wobei die Fäden a) gekräuselt sind.
4. Zusammengesetzte Schichtstruktur nach einem der vorangehenden Ansprüche, umfassend abwechselnde Lagen aus den Schichten (A) und (B).
5. Verfahren zur Herstellung einer zusammengesetzten Schichtstruktur wie in einem der vorangehenden Ansprüche beansprucht, umfassend das Aufeinanderlegen abwechselnder Lagen der Schichten (A) und (B), um eine gestapelte Anordnung zu erhalten, bei der zumindest eine äußere Lage von der Schicht (B) gebildet wird, und Wärmebehandlung der gestapelten Anordnunq, um die Schichten miteinander zu verbinden.
6. Laminat aus zwei oder mehreren Lagen einer zusammengesetzten Schichtstruktur wie in einem der Ansprüche 1 bis 4 beansprucht oder wie nach dem Verfahren des Anspruchs 5 hergestellt.
7. Laminat aus einem gewebten oder gewirkten Stoff, Vliesstoff, Papier, Glasmatte, Film, Folie, Schaumstoffbahn, Wellpappe oder Metallnetz und einer zusammengesetzten Schichtstruktur wie in einem der Ansprüche 1 bis 4 beansprucht oder hergestellt nach einem Verfahren wie in Anspruch 5 angegeben.
EP19800302182 1980-06-27 1980-06-27 Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe Expired EP0043390B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE8080302182T DE3069016D1 (en) 1980-06-27 1980-06-27 Composite sheet structure, process for its preparation and laminates comprising said structure
EP19800302182 EP0043390B1 (de) 1980-06-27 1980-06-27 Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe

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EP19800302182 EP0043390B1 (de) 1980-06-27 1980-06-27 Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe

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EP0043390A1 EP0043390A1 (de) 1982-01-13
EP0043390B1 true EP0043390B1 (de) 1984-08-22

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3887811T2 (de) * 1987-10-15 1994-07-07 Mitsubishi Yuka Badische Faseriger Schichtstoff und Verfahren zur Herstellung desselben.
EP0409993B1 (de) * 1988-12-15 1995-08-23 Asahi Kasei Kogyo Kabushiki Kaisha Komposit-blatt für faserverstärktes material
FR2738770B1 (fr) * 1995-09-15 1997-10-24 Nortene Technologies Materiau en nappe en matiere plastique destine en particulier a la realisation d'ecrans d'occultation pour jardins, terrasses et balcons

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1560778A1 (de) * 1964-06-16 1969-12-04 Freudenberg Carl Fa Verfahren zur Herstellung vond kombinierten Textilverbundstoffen
FR2277172A2 (fr) * 1968-11-26 1976-01-30 Akzo Nv Nappe elastique en fils polymeres synthetiques et procede pour sa fabrication
DE2448299C3 (de) * 1974-10-10 1980-02-14 Fa. Carl Freudenberg, 6940 Weinheim Bindefädengebundener, als Tuftingträgermaterial geeigneter Vliesstoff aus Polyesterfilamenten

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EP0043390A1 (de) 1982-01-13

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