DE2052925A1 - - Google Patents

Description

PATENT LAWYERS
8 MUNICH 8O, MAUERKIRCHERSTR. 45

Dr. Barg Dipl.-Ing. Darn. 8 Munich 80, Mauerkirdierstraee 45 Your reference your letter Our reference date Λ ft » ,, jfVTA

2007 Attorney File $

i'xonsanto Company, St. Louis, Missouri O3166 / U3A

Bonded, nonwoven fiber products and processes too

ilir manufacture

The invention relates to bonded, non-woven fiber products, The binder used is an Ubhylen / Vinylchiorid-Hischpolynierisat contain.

Under the expression "non-woven; it Ji'aseriumaterial" is to be sewn together a tightly pressed mass of fibers, which ontv; eder on mechanise hem, chemical, pneumatisctioii,
oloKbricchem ways or by vacuum or on any other

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Way down and down. in the desired flat (Fabric, mats or! Foils) or three-dimensional shape is brought.

A non-woven fiber material can be used as a wet process as well as a dry process. By doing. wet procedures are the Fibers slurried in water or a similar inert liquid. The slurry is on a flat surface spread out, the inert liquid is allowed to drain and the web is dried under pressure to form a loosely compressed mass of random distributed fibers. In the dry process, the. - fibers with a mechanical or pneumatic device, for example a carding machine or an air coating machine (air-lay machine), when dry on a firm, flat surface, e.g. a conveyor belt, placed. The dry process can be used to precipitate the fibers in either an arbitrary distribution or applied in an oriented distribution. A detailed explanation of the manufacture of nonwoven Weaving is in "! Ton Woven Fabrics", F. N. Buresh-

-. · J., ■ Reinhold Publishing Company, New "Xork, New York" (1 ^ 62), ver

'■ "'. ■ · ■ · '■' ·" · i - '■. ·' · public. ·;

Regardless of the process used to manufacture the

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niciit-woven laser material is used, has that At this point the material only has a thin, delicate structure, which has practically no tensile strength and does not hold together as a single piece without the Iraqis. So that the non-woven JTaseria material is the most practical wki application purposes necessary tensile strength and required The fibers must have ixuide strength (cohesion) connected in some way and fastened to one another. The usual and most economical V \ fe ^, UiU the 'connection and mutual consolidation the iTaser sa is to achieve the non-woven To impregnate or to impregnate fiber materials with a binding agent EÜutigtiii, then to be heated or in another way Activate LU to cause the binder to converge and 3chmel & en to orange and connect the fibers together U.N. to solidify alternately.

jt-i for many purposes it is important that the connected, non-woven products have good elongation, resistance to oils and solvents, good draping

and grip properties, a good anti-friction grip s D it is constantly-Leit u: iü. no discoloration and a high tensile strength (Tensile strength).

: ^ ΐΐ / - · ._ for the non-woven laser products sina Already used in a wide variety of Smiths table general-purpose polymers

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sate and copolymers have been used. Some of these known polymers provide less desirable, stiff pro ' products which are unsuitable for use in textiles because of their poor draping qualities and their hard hand. Other known polymers lead to discoloration and a loss of strength if they are used during washing exposed to bleach. Still other known polymers lead to bonded, non-woven fiber products, which have acceptable elongation properties, but which at the same time suffer a loss of tensile strength. In general, the binders used hitherto have been used not proven entirely satisfactory.

According to the invention, it has now been found that, in the first place, vac. Ne, non-woven Fiber products that have the desired combination of high tensile strength and elongation as well as good grip and Have draping properties, are obtained if one is used as a binder for the non-woven fibrous material Ethylene / vinyl chloride copolymer used.

The bonded, nonwoven fiber products of the present invention can be made from either natural or synthetic Fibers or any combination thereof, the selection of the fiber being dependent only on that for the connected, non-woven fiber product depends on specific end use intended. Examples of fibers that

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■ can be used according to are natural fibers, e.g. B. Wood fibers, jute, sisal, hemp, cotton, linters, silk, Mohair, cashmere, asbestos, wool and glass, as well as synthetic fibers, e.g. B. Beyon fibera, Oellulose ester fibers from for example Cellulose acetate, polyvinyl chloride, polyvinyl acetate, polyacrylonitrile and copolymers thereof, polyethylene, Polypropylene and the like, polyesters such as e.g. B. ethylene glycol erephthalate polymers and polyamides des Nylon type.

In many uses, the joined, non-woven Fiber products of the invention made from several natural fibers or from several synthetic fibers or one ! Combination made of natural and synthetic fibers. Combinations of wood and cotton fibers can be used with Advantageously used in such end products, such as. B. footwear materials and the like. In general the wood fiber makes up the bulk of the fiber content of such bonded, non-woven fiber products. Combinations of glass fibers and asbestos fibers are generally used for insulation purposes. Combinations of glass fibers and Wood fibers are also useful for certain draping purposes. The weight ratio of glass fiber to cellulose fiber is common in such bonded, nonwoven fiber products about 1110 to about 10 »1.

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When used for hard-wearing clothing, a combination of wood fibers and nylon fibers or a Combination of wood fibers and Eeyon fibers can be used. Combinations of wood fibers and nylon fibers and combinations Wood fiber and polyester fiber are also used extensively for various purposes, for the reinforced fabrics are required. With these combinations of natural and synthetic fibers is the weight ratio of natural fiber to synthetic fiber is generally about 20 to about 20: 1 and preferably about 1i1 to about 3 »1.

Those used to make bonded, nonwoven fabrics of the present invention Nonwoven fibrous materials useful in fiber products can be made in any known manner will. The non-woven fiber material can, for example, consist of fibers that are produced in a random manner are deposited, as well as made of fibers oriented or aligned along a specific axis will. Nonwoven fiber materials in the form of two-dimensional webs can be prepared by the following methods getting produced. Oriented fabrics are made using conventional weaving machines, e.g. B. ice wolves, weaving birds, Cards or garnet stones. Crossed lanes work in a similar fashion to oriented lanes produced, but the fibers in exactly the right wind

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no to be placed in the direction of the machine to avoid the crosswise to improve strength.

Randoin fabrics are made in air coating machines and the non-woven fiber material has in all The same strength. In the air coating method v / ground endless threads through a cutter or a pre-card, polygamy the fibers in the output side of a blower. Suitable lines are provided, which the fibers in a collecting sieve or a conduct air-permeable structure in which the fibers are collected in the desired shape. The sieve can be in shape an endless conveyor belt that runs through the lower part of a tower, in the upper part of which the blown Fibers are introduced through the line. A suction box can be arranged under the moving sieve, which supports the deposition of the fibers on it. Instead of a moving flat screen, a stationary shaped screen ([ be used. The sieve can, for example, have the shape of a funnel in the shape of a hat, such as is used in the felt hat making industry is used. It can also be of any other shape suitable for making the desired Shape of the bonded, non-woven fiber product, e.g. B. a right-angled trough. As in the case of the endless conveyor belt can also be below the stationary Sieves to aid in the deposition of the fibers on it

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a suction device can be provided.

• Randoni fabrics can also be sprayed directly can be made from a solution or a molten mass of the fiber material. This is the usual procedure for the production of glass fibers or rock wool fibers as well as those made of nylon or thermoplastic materials that are used in can be dissolved or melted in a suitable solvent. The solution or the melt is in suitable Nozzles or nozzle-shaped openings introduced and against the flow or the flows of the thread-forming material is a Stream of a fluid, such as. B. air, nitrogen or water vapor, directed under high pressure to interrupt them and they are in the vicinity of the openings too! fibers too coagulate. Electrostatic spinning processes can also be used for this purpose. As in the case of using The torn and dispersed fibers can be introduced into the upper part of the settling tower by blowers and with it With the help of suction devices, they can be allowed to sit down on a suitable moving or stationary sieve at the bottom of the tower. This method is particularly suitable for the production of fibers from silicon-containing materials, such as. B. Glass or rock wool, as well as for the production of thermoplastic resin fibers.

Wet Eandom fabrics are made from a slurry of dis-

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■ Pergated fibers on a papermaking machine or a modified papermaking machine. Spunbond fabrics are made from randomly oriented continuous filament fibers produced, which at the erection points with each other are connected. This process comprises the extrusion of the continuous filament fibers, drawing to orient them Paser, a certain intertwining of the fibers by liquids or air and the connection at the crossing points.

The bonded, nonwoven fiber products of the invention are generally made by a process which consists in turning the loose fibers into a nonwoven Compresses fiber material with the structure of the desired connected, non-woven fiber product, the ethylene / vinyl chloride high-polymer binder is dispersed within the non-woven fiber material and heating the impregnated, nonwoven fiber material to a temperature sufficient to produce the interpolymer to converge and melt, and that xaan optionally heated to a temperature which is sufficient to crosslink the copolymer, if a sulfur crosslinking agent is used.

Another method of making those of the present invention verb arid, non-woven fiber product, which is particularly suitable when the non-woven fiber material is after the

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An air coating method is produced in an air coating machine, that the fibers with the Bringing ethylene / vinyl chloride copolymer dispersion or powder into contact when it passes through the settling chamber fall on their depository. This is preferably carried out by using the ethylene / vinyl chloride copolymer dispersion or powder sprayed into the settling chamber at any point between the top and the bottom. By spraying the fibers when they fall onto the collection point, it is possible to produce an even Distribution of the ethylene / vinyl chloride copolymer binder between the fibers before they are collected into the nonwoven fiber material. In the preparation of certain fiber products in which a hot melted A mass of a polymer, for example nylon, or a molten, silicon-containing mass or a glass by blasting heated air or heated water vapor is torn, the binder dispersion or the binder powder can be sprayed directly onto the fibers, while these are still hot, so that the binder sets immediately after deposition and the fibers in the correct relationship to each other connects and solidifies each other.

Those used to make the bonded, nonwoven fabrics of the present invention Fiber products contain suitable copolymers

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generally from about 5 to about 70 weight percent ethylene and about JO "to about 95 weight percent vinyl chloride. The Hischpolynierisate preferably contain about 15 "to about Weight percent ethylene.

The ethylene / vinyl chloride copolymer binders can be applied to the fibers of the nonwoven fiber material by any known method. The ethylene / vinyl chloride copolymer binders are usually applied to the fibers of the nonwoven fiber material by placing them on their surface or by immersing the woven fiber material in a liquid, thickened or foamed dispersion so that the jjindeiiiittel penetrates into the interior of the non-woven fiber material The ethylene / vinyl chloride copolymer binders are usually applied in an aqueous disposition . In a typical application, the fabric is impregnated with the ethylene / vinyl chloride copolymer binder by immersing the fabric in the dispersion dips or soaks in it so that sufficient moisture absorption of the binder takes place. The wetted, nonwoven fibrous material in the form of a nonwoven or a woven fabric can then be passed between a pair of pressure rollers to ground around one substantially

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to achieve uniform impregnation and also to regulate the amount of binder applied. The impregnated, non-woven fiber material is dried in the usual way to all or part of the Water to remove and a confluence and melting of the ethylene / vinyl chloride copolymer within the to effect non-woven fiber material. The drying temperature and the drying time depend on the size, the Shape and cross-section of the impregnated, non-woven fiber material. In general, the drying tempera door adjusted so that no noticeable deterioration or no noticeable degradation of the fibers or the ethylene / Vinyl chloride copolymer occurs.

If the ethylene / vinyl chloride copolymer binders are used in the form of a dispersion, the dispersion contains generally about 5 "to about 90 percent by weight Mixed polymer. These dispersions preferably contain about 10 to about 60 percent by weight of copolymer to facilitate application by dipping, sucking, spraying and the like.

The amount of ethylene / vinyl chloride copolymer binder, based on the weight of the fiber component of the bonded, non-woven fiber product, depending on the desired properties of the end product and the special

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. leu end use can be varied within wide limits. The bonded, nonwoven fiber products of the invention generally contain from about 2 to about 200 percent interpolymer based on the weight of the fibers. For the production of preforms which are to be converted into shaped objects, about 2 to about 10 ° / b ethylene / yinyl chloride copolymer binders, based on the weight of the fibers, are preferably used. In the manufacture of insulating materials, the amount of ethylene / vinyl chloride copolymer binder used generally falls into the lower part of the above range when the binder is primarily applied directly to the surface (s) of the product, or when it is applied in conjunction with other binders is applied.

If the ethylene / vinyl chloride copolymer binder in primarily serves to bond the fibers together to form a bonded, non-woven fiber product, in which the maximum porosity in connection with a minimal change in the jasper handle and the draping properties maintained as well as an increase in tensile strength is achieved, preferably about 10 to about 70 weight percent binder solids based on the Fiber content. The lower part of this range generally provides maximum porosity and minimum r. Change of the fiber grip and the drupier properties,

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while in the upper part of this range the porosity is essentially retained and the fiber feel and drape properties are still clearly present. The on this Manner obtained connected, non-woven fiber products are preferably used for a wide variety of sanitary purposes, for example as table napkins, bibs, Tablecloths, covers for sanitary towels, removable diapers, removable foils, surgical dressings and compresses. When this amount of binder is used, a relatively little or no "window shift", d. H. the spaces between the fibers remain open, so that a highly porous, voluminous product is formed. If desired, the density of the product can be adjusted by applying different prints before, or in many cases after the saturated, non-woven fiber material has been heated for bonding.

Bonded, non-woven fiber products containing about 40 to about 150 percent by weight of ethylene / vinyl chloride copolymer binders, based on the weight of the fiber, are generally used in the clothing industry Manufacture of interlining materials for coats, dresses, collars, lapels and the like and for the manufacture of hard-wearing outerwear, such as B. blouses, squats, shirts, dresses and the like used. Connected, non-woven fiber products that contain the binder

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included in the specified range are also suitable as curtain and drapery materials. Except for the above The bonded, nonwoven fiber products according to the invention can be used in general household and for clothing, which contain 10 to 100 percent by weight of binder, based on the weight of the fiber, for many purposes Light industry, for example as cleaning cloths, filters and lining materials for packaging.

The connected, non-woven fiber products of the invention, the about 100 to about 200 percent by weight binder, based on the weight of the fiber, are particularly suitable for uses in heavy industry who want strength and resistance to wear. Examples of such uses are their use as industrial seals, packaging, filters and the like.

If desired, the aqueous dispersion of the ethylene / Vinyl chloride polymerizate is also a wetting agent that aids the penetration of the nonwoven fiber material to which it is applied. The watery ones Dispersions can also contain a foaming agent or a defoaming agent if the ingredients are aqueous Dispersion have a tendency to foam and if such foaming is undesirable. They can

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common crosslinking agents, such as ζ. B. the sodium salt of Dioctyl succinic acid, and the usual schäuniungs- and Defoaming agents, such as. B. Including sodium soaps Sodium oleatf zuia foaming and octyl alcohol or certain Silicone antifoam agents for defoaming.

In some cases, the properties of the bonded, non-woven fiber products are greatly improved when this llischpolymerisat hardens in the heat to achieve crosslinking. iithylene / vinyl chloride copolymers can with various sulfur-containing compounds such as described in U.S. Patent 3,356,6 ^ 8 is used will. The copolymers are crosslinked by wan the connected, non-woven fiber products after Drying or curing as the final part of the drying step itself, as described in U.S. Patent 3,356,658.

The bonded, nonwoven fiber products of the present invention are characterized by high tensile strength, good elongation, softness, good grip and good flexibility, good draping properties and good resistance to many common solvents and detergents marked. Because of these properties, the connected, non-woven fiber products suitable for a wide variety of uses, including

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• Many have already been mentioned above and of which, for example include use in cardboard box, toilet paper, cleaning wipes, terry towels, packaging for ITahruii ^. ^ Uids products, tea bags, wallpaper, coasters, ■ Napkins, tablecloths, heat or sound insulating materials, Electrolytic capacitors, luggage outer skins and inner linings, strip materials coated with glue, pressure-sensitive strip materials, cover films, Pennants, flags, labels, book cover materials, projection screens, Seals, pressure press cover foils, airtight Wrapping paper, sandpaper backing layers, copy strips, Drapery binders, decorations, binders, ürankenhausartikel, z. 3. Hoods, hats, smocks, jackets, rags (scrub xjantß), capes, shoe protectors, washcloths, pillow cases, Wipes, sanitary napkins, alcohol swabs, surgical dressings, napkins, curtains, drapes, and diapers Foils, filters for the treatment of food, motors, machines, air systems or liquid systems, electric Insulators, strips, ribbons, automobile headrests and armrests, upholstery, support cushions, fiber fillers, Sleeping bags, protective covers, sheets, blankets, curtains, blinds, carpets (non-woven), carpet underlays, hard-wearing clothing, Fabric insulation, undergarments, diapers, interlayer and interlining materials (suits and cuffs), Insoles for shoes, automobile door panels, film backings, Floor cleaning pads, emery pads,

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artificial leather and chamois leather, micropolishing cloths for metals and optical lenses, coatings for plastics, battery separators, Automotive speakers, polishes, decorations and automotive upholstery.

The ethylene / vinyl chloride copolymer binders were as the only binder for the inventive

k bound, non-woven fiber products described for However, the copolymers can be used for some purposes also in combination with pre-condensate resins that cure in the heat, such as. B. aminoplasts, are used, the can interact with the ethylene / vinyl chloride miseh polymer binders, which improves the washing properties and the dry cleaning resistance of the bonded, non-woven Fiber products are improved, especially when they are in the form of a fabric material. The ones with the Ethylene / vinyl chloride copolymers, preferably mixed

^ Aminoplast resins are the condensation products or precondensates of urea and formaldehyde, ethylene, urea and formaldehyde and of formaldehyde and melamine, including

the
Borrowed / alkylated precondensates »of urea / formaldehyde and melamine / formaldehyde. Typical examples of these aminoplasts are the reaction products of formaldehyde and ICriazines, for example melamine and the alcohol-modified melamine / Fox'maldehyde condensates, which are obtained by reaction with a lower alcohol, e.g. B. methyl or ethyl alcohol,

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have been etherified.

If an auxiliary is used together with the sbindeiaittel ethylene / vinyl chloride copolymers, it may in !! close up to about ^c j0 weight percent, based on the weight of üthylen / V'inylclilorid-Mischpolymerisatbindenii'ctels used, wherein a Henge from about 10 to 15 weight percent iüiiinoplast is preferably used.

The ethylene / vinyl chloride copolymers which can be used according to the invention can easily be produced by the most varied of known processes. The ethylene / vinyl chloride copolymers used according to the invention can be prepared by a process which consists in reacting the jithyleii- and vinyl chloride monomers in the presence of an alkaline, buffered Eedox catalyst system, in the presence of water and about 1 to about 8 percent by weight , based on the monomer charge, or about 4 to about 7 percent by weight, based on the polymer product, of a nonionic emulsifier having an HLB value (hydrophilic-lipophilic balance of an emulsifier) of about to about 17 and the mixture at one temperature (-10 ° 0 to about 25 ° 0) and a pressure (35 to 2460 kg / cm ² ffi) Q to 35-000 psi7) so long that the polymerization of the honey is effected. Examples of other suitable emulsifiers are anionic emulsifiers with a

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HLB value of at least 10. This method is in the United States patent 3 4Ό9 568 described in more detail, the subject matter is expressly included in the present application.

The following example is intended to explain the invention in more detail. The parts and percentages given therein are, if nothing otherwise stated, based on weight.

example

A pre-weighed sample of Kolligsworth's non-woven and Vose fabric, which is made from 75 percent by weight cellulose fiber ^! and 25 percent by weight mylon fibers was put into a Aqueous dispersion of an ethylene / vinyl chloride copolymer binder immersed. The aqueous dispersion contained 13-5 percent by weight of polymer solids and that iixschpolymerisat contained 76 percent by weight of ethylene and 24 weight percent vinyl chloride. The impregnated fabric was passed through a size press, weighed, about 2 minutes long dried at a temperature of about 118 ° C and weighed. The amount of binder in the bonded, non-woven Fabric was 35 »2 percent by weight based on weight of the non-woven fabric. The connected, non-woven Fabric was calendered through a single nip for smoothing and examined for its grip and drape properties and its tensile strength. The handle and drape

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Properties were determined qualitatively by touching and the results obtained are on a scale of 1 to 10 specified. The number 1 means that the fabric was very soft and very flexible. The number 10 means that he was very rough and not flexible. The tensile strength was determined according to TAPPI 14-0403-61 with an ins tr on table. The bonded non-woven fabric had good hand and drape properties (5), and it had tear resistance 1.61 kg / cm wide (9 »0 lbs / inch).

Patent claims:

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Claims (1)

Claims Connected, non-woven fiber product, characterized in that it is made from a non-woven fiber material consists, which with an ethylene / vinyl chloride copolymer binder that is about ^ to about 70 percent by weight Ethylene and about JO to about 95 weight percent Contains vinyl chloride. 2. Product according to claim 1, characterized in that the non-woven fiber material consists of natural fibers. J. Product according to claim 2, characterized in that the fibers are oilulose fibers or glass fibers. 4. Product according to claim 1, characterized in that * the non-woven fiber material consists of synthetic fibers. 5 · Product according to claim 4, characterized in that the fibers are polyester fibers or polyamide fibers. 6. Product according to claim 1, characterized in that the non-woven fiber material is a combination of natural Represents fibers and synthetic fibers. 109819/1786 - 23 - 7 · Product according to claim 1, characterized in that the non-woven fiber material in the form of a two-dimensional thread Web is present. o. A product according to claim 1, characterized in that the iLthylell / Vinylclilorid-l·lischpol _t ynerisat about 15 to about 30 percent ethylene and contains about 70 to about 35 percent vinyl chloride. 9 · Product according to claim 1, characterized in that the non-woven fiber material is a combination of natural-Γ --- ϊ ^ -ϋ and synthetic fiber: ', ^ arsti-llt and that that Ethylene / viral chloride polymerizate about 15 to about 30 Percent ii.tb.ylen and about 70 to about 85 percent vinyl chloride contains. 10. Product according to claim 9j, characterized aass the natural fibers are cellulose fibers. 11. Product according to claim 10, characterized in that » the Oellulosefaserii are wood fibers. 12. Product according to AnspxTich 9j, characterized in that the synthetic fibers polyamide or polyester fibers sino 13 · ii'ouai.t according to claim 9, characterized in that 109819/1786 - 24 - 24- -. ■ natural fibers cellulose fiber, and the fibers are polyamide or polyester fibers 14. Product according to claim 9, characterized in that the combination of JP fibers at least 50 percent by weight of fibers from the group of cellulose fibers, polyamide fibers, vinyl acetate fibers, fibers from polymers and Hischpoly-, Luerisaten of acrylonitrile, poly-Cäthylenenslycol- terephthalate) - W: contains fibers and mixtures thereof. 15 «Product according to claim 1, characterized in that:> that the non-woven fiber material consists of wood fibers, and that the ethylene / vinyl chloride lüsch polymerizat about 15 to about 30 percent ethylene and about 70 to about 85 percent Contains vinyl chloride. . ,. ' 16. Product according to claim 1, characterized in that ' fc the non-woven S'asermaterial a combination of poly- and wood fibers and that the ethylene / vinyl chloride interpolymer is about 15 to about 30 percent Contains ethylene and etvra 70 to about 85 percent vinyl chloride. 17y method:; ur making a ver Dundeiieii, non-gewecteii Li'aücrprodukts in particular according to "claims 1 to 1G, last through ^, ekonn shows that one hates a fiber 109819/1786 " ² ~ ■ compressed into a non-woven fiber material, inside dispersing a binder in the material and heating the material obtained to a temperature sufficient to about the convergence and (melting of the binder to effect within the material, an ethylene / vinyl chloride copolymer being used as the binder, the about 5 to about 70 weight percent ethylene and about 30 contains up to about 95 percent by weight vinyl chloride. 18. The method according to claim 17, characterized in that The binder in the material is dispersed by treating the material with an aqueous dispersion of the binder brings in touch. 19 · The method according to claim 17, characterized in that a non-woven fiber material is used, which in the form a two-dimensional SOIie is present. 20. The method according to claim 17, characterized in that the material is brought into contact with the binder in a settling chamber. 21. The method according to claim I7, characterized in that a non-woven fiber material is used, the one Represents combination of natural and synthetic fibers and that an ithylen / '/ iriylchlorid-Mischpolyiiierisat ver 109819/1786 - 26 - is used, which is about 15 to about JO percent ethylene and contains about 70 to about 85 percent vinyl chloride. 109819/1786