U.S. patent application number 09/909199 was filed with the patent office on 2002-03-14 for structure textile material made of at least two base nonwoven fabrics and method for its manufacture.
Invention is credited to Laun, Heinrich, Passler, Michel, Stein, Karlheinz.
Application Number | 20020029445 09/909199 |
Document ID | / |
Family ID | 7834381 |
Filed Date | 2002-03-14 |
United States Patent
Application |
20020029445 |
Kind Code |
A1 |
Stein, Karlheinz ; et
al. |
March 14, 2002 |
Structure textile material made of at least two base nonwoven
fabrics and method for its manufacture
Abstract
The invention relates to a structured textile material made of
at least two different, needled base nonwoven fabrics. The base
nonwoven fabrics have a structure obtained by needling from at
least one side. The needles used for the structure needling are
fork needles or crown needles, and the depth of the forks and
barbs, respectively, is so selected that, when piercing through,
they completely fill up with fibers of the base nonwoven fabric
facing the needles. The textile material have unmixed, pure fibers
in the pattern, in the background and on the reverse side.
Inventors: |
Stein, Karlheinz; (Hamsbach,
DE) ; Laun, Heinrich; (Augsburg, DE) ;
Passler, Michel; (Neusass, DE) |
Correspondence
Address: |
KENYON & KENYON
ONE BROADWAY
NEW YORK
NY
10004
US
|
Family ID: |
7834381 |
Appl. No.: |
09/909199 |
Filed: |
July 19, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09909199 |
Jul 19, 2001 |
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09109444 |
Jul 2, 1998 |
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6287407 |
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Current U.S.
Class: |
28/112 ; 156/148;
156/309.6; 28/107 |
Current CPC
Class: |
A47L 13/16 20130101;
D04H 1/4374 20130101; D04H 11/08 20130101; D04H 1/498 20130101 |
Class at
Publication: |
28/112 ; 28/107;
156/148; 156/309.6 |
International
Class: |
D04H 011/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 2, 1997 |
DE |
197 28 178.8 |
Claims
What is claimed is:
1. A structured textile material comprising: at least two
different, needled base nonwoven fabrics, the base nonwoven fabrics
having a structure obtained by needling from at least one side with
needles, the needles used for the structure needling being fork
needles having forks or crown needles having barbs, wherein the
depth of the forks and barbs, respectively, is so selected that,
when the needle pierces through the fabric, it fills up completely
with fibers of the base nonwoven fabric facing the needles, and the
textile material has unmixed, pure fibers in the pattern formed by
the needling, both in the background and on the reverse side.
2. The textile material as defined by claim 1, wherein the base
nonwoven fabrics comprise thermoplastic fibers, the fabrics are
laminated to one another, and the bonding of the two base nonwoven
fabrics is further strengthened by activation of the thermoplastic
fibers.
3. The textile material as defined by claim 2, wherein at least one
base nonwoven fabric has thermoplastic fibers whose properties are
so selected that they are not activated during the lamination
process.
4. The textile material as defined by claim 1, wherein an
intermediate layer made of a material capable of glueing the two
base nonwoven fabrics, in particular an adhesive nonwoven fabric,
is introduced between the two base nonwoven fabrics having
thermoplastic fibers, and the two base nonwoven fabrics and the
intermediate layer are bonded by activating the intermediate layer
and the thermoplastic fibers.
5. The textile material as defined by claim 1, wherein
pierce-through sides of the base nonwoven fabrics, bonded by
needling from one side. face each other.
6. The textile material as defined by claim 1, wherein the base
nonwoven fabrics have different material properties, particularly
with respect to cleaning ability.
7. A method for producing a structured textile material that is
made of at least two different base nonwoven fabrics, each having a
characteristic color, comprising the steps of: providing at least a
first base nonwoven fabric and a second base nonwoven fabric that
differs from the first nonwoven fabric, both the first and second
nonwoven fabrics containing thermoplastic fibers; laminating the
first base nonwoven fabric to the second base nonwoven fabric
without activating the thermoplastic fibers contained therein;
needling at least one side of the laminate to create a structured
pattern thereon; and activating the thermoplastic fibers of the
base nonwoven fabrics, wherein the resulting textile exhibits the
starting color of-one of the fabrics, unmixed with the starting
color of the other of the fabrics in the pattern, background and
reverse side of the laminate.
8. The method as defined by claim 7, wherein the needling step is
performed by a needle bearing a fork, which completely fills with
the fibers of the nonwoven fabric that it initially penetrates as
it penetrates that fabric.
9. The method as defined by claim 7, wherein the needling step is
performed by a needle bearing a crown, which completely fills with
the fibers of the nonwoven fabric that it initially penetrates as
it penetrates that fabric.
10. The method as defined by claim 7, further comprising the step
of needling the laminate on both sides.
11. The method as defined by claim 7, wherein the base nonwoven
fabrics are selected so that they have different material
properties.
12. The method as defined by claim 11, wherein the base nonwoven
fabrics differ in their cleaning ability.
13. A textile made by the method set forth in claim 7.
14. A method for producing a structured textile material that is
made of at least two different base nonwoven fabrics, each having a
characteristic color, comprising the steps of: providing at least a
first base nonwoven fabric and a second base nonwoven fabric that
differs from the first nonwoven fabric, both the first and second
nonwoven fabrics containing thermoplastic fibers; inserting an
intermediate layer of material capable of adhesive connection to
the first and second nonwoven fabrics and laminating the first base
nonwoven fabric, the intermediate layer, and the second base
nonwoven fabric to form a laminate, without activating the
thermoplastic fibers contained therein; needling at least one side
of the laminate to create a structured pattern thereon; and
activating the intermediate layer and the thermoplastic fibers of
the base nonwoven fabrics, wherein the resulting textile exhibits
the starting color of one of the fabrics, unmixed with the starting
color of the other of the fabrics in the pattern, background and
reverse side of the laminate
15. A method as for producing a structured textile as set forth in
claim 14, wherein the intermediate layer in a nonwoven fabric.
16. The method as defined by claim 14, wherein the needling step is
performed by a needle bearing a fork, which completely fills with
the fibers of the nonwoven fabric that it initially penetrates as
it penetrates that fabric.
17. The method as defined by claim 14, wherein the needling step is
performed by a needle bearing a crown, which completely fills with
the fibers of the nonwoven fabric that it initially penetrates as
it penetrates that fabric.
18. The method as defined by claim 14, further comprising the step
of needling the laminate on both sides.
19. The method as defined by claim 14, wherein the base nonwoven
fabrics are selected so that they have different material
properties.
20. The method as defined by claim 19, wherein the base nonwoven
fabrics differ in their cleaning ability.
21. A textile made by the method set forth in claim 14.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention is directed to the field of structured
textile materials that are made of at least two different base
nonwoven fabrics, and which find particular application as a
cleaning textile.
BACKGROUND OF THE INVENTION
[0002] A cleaning textile, made of a structured textile material
composed of at least two base nonwoven fabrics, is known from WO 94
23 634. Furthermore, WO 90 14 039 shows a structured, textile,
surface-area material that is made of one nonwoven fabric, from
which a multitude of thread loops or fiber ends are raised by
needling.
[0003] A method for its manufacture is disclosed in the British
patent 2 162 213. There, the structures are produced by needling a
nonwoven fabric, such that fibers or filaments are pulled out from
the opposite surface with the assistance of barbs. As a consequence
of this method, the structures are made principally from material
taken from the respective opposite surface.
[0004] The disadvantage of known structured textile materials made
of at least two different, unbonded base nonwoven fabrics is that
in needling the two unbonded base nonwoven fabrics, a base nonwoven
fabric in a mixed color results on the side where the needle comes
out. When producing the structures by through-needling the fibers
of one base nonwoven fabric through the other base nonwoven fabric,
further mixed effects also result which degrade the appearance of
the finished textile material and also weaken the specific service
properties of the fibrous material of a base nonwoven fabric.
[0005] There remains a need for a structured textile material
formed from at least two different base nonwoven fabrics, in which
such a mixture of the fibers is avoided.
SUMMARY OF THE INVENTION
[0006] According to the invention, the base nonwoven fabrics have a
structure obtained by needling from at least one side. The needles
used for the structure needling are fork needles or crown needles,
and the depth of the forks and barbs, respectively, are selected so
that when piercing through, they fill up completely with fibers of
the base nonwoven fabric facing the needles. Consequently, the
textile material produced is characterized by unmixed, pure fibers
in the pattern, in the background and on the reverse side.
[0007] A textile material having these features has the advantage
that the specific service properties of the fibrous material of a
base nonwoven fabric are retained during the structuring. In the
case where base nonwoven fabrics of different colors are used, the
pure original colors are maintained in the pattern, both in the
background and on the reverse side. This permits the attainment of
various desired visual effects.
[0008] To increase the interlaminar strength of the textile, the
base nonwoven fabrics, having thermoplastic fibers, can be
laminated to one another, and the bonding of the two base nonwoven
fabrics can then be further strengthened by activating the
vertically positioned thermoplastic fibers. In principle, all known
methods and all known binding agents are usable for the laminating,
however, it is preferable to utilize those known methods that
impart a good bond and a negligible stiffening of the textile
material, and furnish a launderability of at least 60.degree. C.,
and preferably 95.degree. C.
[0009] Advantageously, at least one base nonwoven fabric contains
thermoplastic fibers whose properties are so selected that they are
not activated during the laminating stage. It then becomes possible
to provide the unbonded base nonwoven fabrics with the desired
structures by needling.
[0010] In the same way, the lamination of the two base nonwoven
fabrics can be augmented by an intermediate layer made of a
material capable of glueing the two base nonwoven fabrics together.
This intermediate layer can take the form of an adhesive nonwoven
fabric (such as a layer of fibers bonded with adhesives) that can
be introduced between the two base nonwoven fabrics having
thermoplastic fibers. The two base nonwoven fabrics and the
intermediate layer can be bonded by activating the thermoplastic
fibers and the intermediate layer. While it is possible that
portions of the intermediate layer will be needled into the
structure, this is desirable under some circumstances, and can be
exploited to increase the interlaminar strength.
[0011] Although, in general, the choice of the sides of the
nonwoven fabrics to be joined does not matter for the present
invention, it is advantageous that the pierce-through sides of the
base nonwoven fabrics, reinforced by needling from one side, be
facing one another.
[0012] To intensify the effect of the structurings, the base
nonwoven fabrics can have different material properties,
particularly as relating to cleaning ability.
[0013] One method according to the invention calls for laminating
the two needled base nonwoven fabrics having thermoplastic fibers,
without activating the thermoplastic fibers. A structure-needling
process is subsequently carried out on one or two sides, and is
followed by the activation of the thermoplastic fibers of the base
nonwoven fabrics. The result is a structured textile material that
is made of at least two different base nonwoven fabrics having
structures on one or two both sides formed by needling, in which
the textile material retains unmixed, pure fibers in the pattern,
in the background and on the reverse side.
[0014] Compared to a textile material made of two different
nonwoven fabrics needled together, one has the advantage that,
until the structuring, the base nonwoven fabrics remain unmixed.
The needed strength of the base nonwoven fabrics is obtained by
separate needling of the two base nonwoven fabrics before the
lamination process.
[0015] In another method, prior to feeding the textile laminate
into a structure-needling machine, an intermediate layer made of a
material capable of glueing the two base nonwoven fabrics, in
particular an adhesive nonwoven fabric, is introduced between the
two needled base nonwoven fabrics having thermoplastic fibers. The
two base nonwoven fabrics and the intermediate layer are subjected
together to a structure-needling process on one or two sides.
Subsequently, the two base nonwoven fabrics and the intermediate
layer are bonded by activating the thermoplastic fibers and the
intermediate layer. The result is a structured textile material
that is made of at least two varicolored base nonwoven fabrics and
has structures on one or two sides formed by needling, the textile
material having unmixed, pure fibers in the pattern, in the
background and on the reverse side.
[0016] This method is especially suited for one-sided structuring.
However, it is also usable for structuring on both sides if so much
stability is produced by the first pattern, applied on one side,
that a second passage is possible without shifting the layers
relative to each other.
[0017] To attain the best possible purity of the fibers, the
process should is advantageously conducted such that the fork
needles or crown needles used for the structure needling step
completely fill up with fibers of the base nonwoven fabric facing
the needles as they pierce them.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The drawings show a textile material according to the
invention, in which:
[0019] FIG. 1 is a vertical sectional view through the textile
material of the invention; and
[0020] FIG. 2 is a top plan view onto a textile material that has
been structured on both sides.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A laminate according to the invention is produced from two
different, needled, base nonwoven fabrics 1 and 2, shown in FIG. 1,
having the desired weight and the desired material properties. In
the illustrated embodiment, the laminate is made up of two layers
of pure material (material having a uniform characteristic). The
two base nonwoven fabrics 1 and 2 are laminated to one another via
an adhesive zone 3, which can be an adhesive nonwoven fabric.
[0022] Activation of the thermoplastic fibers contained in base
nonwoven fabrics 1 and 2 is avoided during the laminating process,
so that structures 4 can subsequently be produced by needling.
[0023] The structures are produced on a structuring needle machine
such as Dilo, Di-Loop or other, with the assistance of fork needles
or crown needles. In so doing, the depth of the forks and barbs,
respectively, must be adjusted to the fiber quantity of the
nonwoven fabric on the insertion side, so that they fill up
completely with the fibers of this nonwoven fabric.
[0024] The structured laminate is subsequently thermoset. In so
doing, the thermoplastic fibers contained in the base nonwoven
fabric are activated. They bond the remaining fibers to one another
and increase the strength of the base nonwoven fabrics.
[0025] During the process of needling the individual base nonwoven
fabrics, and when structure-needling the laminate, the
thermoplastic fibers (according to their portion in the fiber
mixture) are needled transversely through the material. This has
the beneficial consequence that after their activation, the
transverse stability or interlaminar strength of the textile
material is enhanced.
[0026] When using an adhesive nonwoven fabric 3 arranged between
base nonwoven fabrics 1 and 2, it is possible to allow the two base
nonwoven fabrics 1 and 2 to feed into the structure-needling
machine together with adhesive nonwoven fabric 3, and to structure
all three layers together by needling.
[0027] Provided that there is sufficient resistance of the laminate
against displacement of the individual layers due to the needled-in
structure 4, it is possible to turn the laminate over and to feed
it to the machine once more.
[0028] The thermoplastic fibers in the two base nonwoven fabrics
and, in the same way, the adhesive nonwoven fabric, are
subsequently activated in a procedure for the lamination of the two
base nonwoven fabrics 1 and 2. This is easily possible if the
thermoplastic fibers and the material of the adhesive nonwoven
fabric are adjusted to each other according to the activation
conditions needed.
[0029] Both procedures, with the assistance of two structuring
processes, then allow the introduction of structural features 5 and
6, (as shown in FIG. 2) into both sides of the textile material.
These structurings 5 and 6 can take the form of broken stripes
running lengthwise which, to avoid over-needling, have a lateral
safety spacing d of at least 5 mm.
[0030] Structurings 5 are needled from the side facing the observer
onto the side facing away from the observer, so that only slits or
recesses are visible.
[0031] Structurings 6 are needled from the side facing away from
the observer onto the side facing the observer, so that here the
fiber tufts jutting out above the base nonwoven fabric are
visible.
[0032] The invention has proven particularly successful in the
manufacture of color-pure patterns from two differently colored,
base nonwoven fabrics. If a pattern is needled on one side by a
structure-needling machine into a laminate composed of two colored,
needle-punched nonwovens which can be thermoset, then, in the case
of a red and a blue needle-punched nonwoven, for example, dependent
upon the selected insertion side of the structure needles, the
following product is formed:
1 Insertion side red Insertion side blue Patterning/Structuring Red
Blue Background around Blue Red the patterning Reverse side Red
Blue
[0033] All colors are unmixed.
[0034] If structuring is carried out on both sides, thus both sides
are structure-needled alternately in stripe sectors over the width
of the material during two operations, a product is obtained which
is structured, alternating, corresponding to these stripe sectors
on the top and bottom side.
[0035] In this case, the structuring on the one side is red, on the
other side blue. The color of the background and of the reverse
side in each case is then as shown in the preceding table.
[0036] The unstructured spacings 7, having the width d, between the
opposing stripe sectors 5 and 6, correspond in color to the base
nonwoven fabrics before they are fed into the structure-needling
machine.
* * * * *