U.S. patent number 3,620,892 [Application Number 04/727,325] was granted by the patent office on 1971-11-16 for dimensionally stable articles and method of making same.
This patent grant is currently assigned to Allied Chemical Corporation, New York, NY. Invention is credited to Gene C. Weedon, George H. Collingwood, Robert C. Wincklhofer.
United States Patent |
3,620,892 |
|
November 16, 1971 |
DIMENSIONALLY STABLE ARTICLES AND METHOD OF MAKING SAME
Abstract
Dimensionally stable articles are produced from heat-treating
fabric comprised of multiconstituent filaments prepared from
blended fiber-forming polymeric materials having different
properties, at least one of the fiber-forming polymeric materials
being dispersed as discontinuous fibrils in a lower melting matrix
formed by another polymeric material, and natural or synthetic
filaments which may or may not have heattreating capabilities. The
article is produced by preforming the fabric, during production of
the fabric itself or by subsequent operation, and heating the
latter to a temperature equal to or above the melting temperature
of the multiconstituent matrix material but below that of the
dispersed polymeric material, for a time sufficient to impart a
shape stabilized property to the multiconstituent filaments and
consequently to the fabric article. The multiconstituent filaments
are present in the fabric as individual yarn or filament elements
in combination with other materials, or are present in a
mechanically blended fiber or yarn with other materials. 15 Claims,
No Drawings
Inventors: |
Robert C. Wincklhofer
(Richmond, VA), Gene C. Weedon (Richmond, VA), George H.
Collingwood (Hopewell, VA) |
Assignee: |
Allied Chemical Corporation, New
York, NY (N/A)
|
Family
ID: |
27505574 |
Appl.
No.: |
04/727,325 |
Filed: |
May 7, 1968 |
Current U.S.
Class: |
428/197; 156/181;
264/322; 442/199; 264/122; 428/397; 442/311; 442/361 |
Current CPC
Class: |
D02G
3/402 (20130101); D03D 1/00 (20130101); F02B
53/00 (20130101); D04B 1/16 (20130101); D06M
23/06 (20130101); D06N 3/0004 (20130101); D04H
1/54 (20130101); D03D 15/47 (20210101); D06M
23/00 (20130101); D03D 15/00 (20130101); D10B
2503/04 (20130101); D10B 2331/00 (20130101); Y10T
442/444 (20150401); D10B 2331/02 (20130101); Y02T
10/12 (20130101); Y10T 442/3146 (20150401); Y10T
428/2481 (20150115); Y10T 428/29 (20150115); D10B
2505/08 (20130101); Y10T 442/637 (20150401); D10B
2401/062 (20130101); D10B 2501/04 (20130101); Y10T
428/2929 (20150115); Y10T 428/24818 (20150115); Y10T
442/611 (20150401); D10B 2331/04 (20130101); D10B
2401/041 (20130101); D10B 2501/043 (20130101); Y10T
428/2973 (20150115); D10B 2403/0114 (20130101); D10B
2501/06 (20130101) |
Current International
Class: |
D03D
1/00 (20060101); D06M 23/00 (20060101); D03D
15/00 (20060101); D06M 23/06 (20060101); D06N
3/00 (20060101); D04H 1/54 (20060101); F02B
53/00 (20060101); D04h 001/04 (); D03d 015/02 ();
D02g 003/36 () |
Field of
Search: |
;161/72,88,89,150,170
;260/857 ;264/171F,171R,122,322 ;156/181,306 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Robert F. Burnett
Assistant Examiner: Roger L. May
Attorney, Agent or Firm: Roy H. Massengil
Claims
1. A dimensionally-stable fibrous structure comprised of a
heat-treated, fusion bonded textile material; said textile material
being comprised of a blend of (a) a first component of
multi-constituent filaments spun from at least two different
polymeric materials such that, in a given filament, a first
fiber-forming polymeric material defines a matrix and a second
polymeric material is dispersed therein in the form of
discontinuous fibrils, said matrix comprising at least 50 percent
by weight of the filament and having a lower melting point than
said dispersed fibrils, and (b) a second component of fibrous
material selected from the group consisting of those natural,
synthetic or inorganic materials which are capable of withstanding
the heat required to elevate the multi-constituent filaments to at
least the melt temperature of the matrix thereof; and said textile
material having been heat-treated at a temperature in the range
above the melting point of the matrix but below the melting point
of the dispersed fibrils such that the multiconstituent filaments
thereof are set and fusion bonded at least at their cross points
without substantial polymer flow, disfiguration, and
cross-sectional flattening; whereby a textile appearance is
aesthetically retained and said fused textile material is
characterized by an enhanced stiffness, shape stability and
2. The product of claim 1 wherein the multiconstituent filaments
are melt spun from at least two fiber-forming thermoplastic
polymers of which said matrix-forming polymers has a melting index
at least 10.degree. C. lower
3. The product of claim 2 wherein the said matrix-forming polymer
comprises
4. The product of claim 3 wherein the multiconstituent filaments
comprise
5. The product of claim 4 where polymer forming the matrix of said
multiconstituent filaments is selected from the group consisting
of
6. The product of claim 4 wherein the dispersed fibrils are formed
from a polymer selected from the group consisting of polyolefins,
polyamides,
Description
In a previous development, multiconstituent filaments were produced
having a nylon matrix with microfibers of polyester dispersed
therein. These filaments (described and claimed in Twilley U.S.
Pat. No. 3,369,057, (which patent is hereby incorporated by
reference as if fully set out herein) were originally prepared for
employment in high strength yarns useful in yarn or cord form as
reinforcing strands in elastomeric tires, conveyor belts, seat
belts, hoses, and the like. In particular, when used to reinforce
tires, the Twilley filaments have a higher tensile modulus than do
normal polyamide filaments from the same polyamide, and
significantly lower cured strength loss, thereby producing stronger
and more durable tires with much less undesirable flat
spotting.
In a companion development with this invention, it was discovered
that fabric made from multiconstituent filaments could be heated
under appropriate conditions to produce novel articles of improved
dimensional stability, with good stiffness, moldability, wrinkle
resistance, and other desirable properties, yet even after
heat-treating the fabric retains its textile appearance. The
multiconstituent filaments do not flow or substantially change size
as they are fused together during heating, thereby permitting
controllable porosity, coloration, texture and other fabric
appearance properties combined with the above-mentioned shape
stabilization resulting from heat-treating, i.e., the
multiconstituent fibers fuse together individually along their
lengths, at their cross points, and with any other filaments or
yarn having ingredients capable of melting or tacking at the
heat-treating temperature. These products have permanent shape
retention even after repeated laundering and severe abrasive
abuses.
SUMMARY AND OBJECTS
In accordance with this invention, it has been discovered that
multiconstituent filaments can be combined with other natural or
synthetic filaments to form fabric which can be heat-treated to
produce articles similar to those mentioned above yet which can
utilize the properties of the various other filamentary materials
to vary the final product characteristics and economics. The
principal object of the invention is, therefore, to provide novel
fabric articles dimensionally stabilized by fusing multiconstituent
filaments incorporated in the article in a mechanically blended
fiber or in the form of individual filaments or yarns woven,
knitted or pressed together with other filaments. Other objects
will be apparent to those skilled in the art from the following
description and appended claims. As used herein, the term
multiconstituent filament means filaments made by inclusion of at
least one polymeric material in a matrix of another as
discontinuous fibrils, the two materials having melt temperatures
at least 10.degree. C. apart such that fibrous structures composed
thereof can be heat-treated by application of heat below the melt
temperature of one and equal to or above that of the other, the
entire filament composition or any component thereof optionally
including any secondary material compatible with the heat-treating
property of the fabric as a whole such as antioxidants and other
stabilizing agents, reinforcing particles, fillers, adhesion
promoting agents, fluorescent materials, dispersing agents, and
others useful in polymerization, extruding, spinning, fabric
forming and shaping, heat-treating and product finishing
techniques. By selectively blending these types of fibers desirable
properties can be built into a product that can be heat-set to
provide permanent shape retention without the aid of bonding agents
while maintaining the aesthetic qualities thereof.
DESCRIPTION
Multiconstituent filaments are produced by combining two different
thermoplastic polymeric materials preferably, although not
necessarily, having melting points approximately 25.degree. C.
apart. A major amount of one of the materials is utilized as a
matrix in which the other is dispersed. The preferred polymeric
materials are nylon 6 (50-90 parts by weight) and polyethylene
terephthalate (10-50 parts by weight). The precise nature of these
preferred materials and the preferred manner in which they are
blended together are fully disclosed in the above cited Twilley
patent and reliance on the disclosure therein is made for any
details.
In addition to the Twilley multiconstituent materials, other
thermoplastic polymers and copolymers alone or in combination may
be used such as polyamides, polysulfones, polyphenylene oxides,
polycarbonates, polyesters and polyolefins, again with the matrix
being present in a major amount and the higher melting dispersion
being dispersed in discontinuous fibrils therein, in accordance
with the blending principles established in the Twilley
disclosure.
Polyesters and polyamides are preferably of the type disclosed in
the Twilley patent. Other suitable polyamides are nylon 6/6
(hexamethylene-diamine-adipic acid), nylon 6/10
(hexamethylene-diamine- sebacic acid) methanol- and ethanol-soluble
polyamide copolymers, and other substituted polyamides such as the
alkoxy substituted polyamides. Suitable polyolefinic materials are
polyethylene, polypropylene, poly-1butene, poly-2-butene,
polyisobutylene, polystyrene, and similar materials.
In fabric association with the multiconstituent filaments, a wide
variety of materials useful in producing fabric may be used,
including natural fibers, modified natural fibers and synthetic
fibers. For example, useful natural fibers are: animal fur, rabbit
hair, wool, worsted, vegetable fibers such as cotton, flax, linen,
hemp, jute, kenaf, pineapple fiber, ramie and sisal, and mineral
fibers such as asbestos, glass fibers and spun glass. Modified
fibers include cyanoethylated cotton, mercerized cotton and
non-shrinkable wool. In addition to those specified above, other
suitable synthetics are Vinyon-N (manufactured by Carbide and
Carlon Corporation by copolymerization of vinyl chloride and
acrylonitrile), Saran (a vinyl chloride polymer manufactured by Dow
Chemical Company), Orlon, Dacron and Teflon having well-known
formulations. Still other examples of materials are polyureas,
polyacrilonitrites, polyvinyl alcohol, etc. The only limiting
criterion for this particular ingredient is that it occurs as, or
may be processed into, a filament which is further capable of
withstanding the temperature necessary to fuse the multiconstituent
filaments and being included in the structure of a textile
material, whether woven, nonwoven, knitted, etc.
The following (example A) is the preferred method of carrying out
the invention and illustrates the generally applicable principles
hereof. A fiber was prepared according to example 1 of the
above-mentioned Twilley patent, i.e., nylon 6 and polyethylene
terephthalate, 70 and 30 parts by weight respectively, were heated
and blended substantially homogeneously, and spun and drawn so that
the final yarn denier was 70 grams per 9000 meters. From this a
textured 2 ply/70 denier/16 filament yarn was made. Commercially
available nylon 6,6 (70/34 denier/filament) was mixed by the Taslan
process to give a 33 percent by weight multiconstituent 67 percent
by weight nylon 6,6 yarn which was then knitted into a 1 by 2 rib
knit fabric. The fabric was placed over a 6 inch circular hoop with
a friction retaining ring and subsequently exposing the fabric to
temperatures above the melting point of nylon 6 but below that of
the polyethylene terephthalate. The minimum fusion time was
approximately 10 seconds at an optimum temperature of 240.degree.
C. within the preferred range of 230.degree.-250.degree. C. The
resulting data shown below in table I indicates dramatically the
effects of heat-treating in terms of stiffness but without loss of
fabric appearance. Such dimensionally stabilized fabrics are useful
in the production of wall coverings, upholstery for boats,
automobiles, planes, in such apparel as hats, shoes, wrinkle
resistant garments or portions thereof, and in many other
applications.
TABLE I ##SPC1##
Various other methods of combining multiconstituent and
non-multiconstituent filaments can be employed. They can be
employed as yarn ends or filaments as separate ends in the
production of a fabric by known techniques. They can also be formed
into a mechanically blended filament by plying two or more
different ends together, paralleling two or more ends as one at
takeup or coning, entangling two or more different ends either by
air or elastrostatic process (either commingle or Taslan) knitting
two or more different yarns as one through the same guides, core
spinning one yarn with a sheath of another yarn, staple blending
different fibers, texturing different ends together or by matting
by known techniques.
In another embodiment of the invention, a fabric may be knitted
into a fabric having one side predominantly multiconstituent yarn
and the other side a nonmulticonstituent.
To illustrate in example A above, instead of utilizing a blended
yarn comprised of multiconstituent filaments and nylon 6,6
filaments, these same materials are knitted as separate ends into a
Swiss pique fabric using conventional equipment, one side of which
is predominantly multiconstituent and the other nylon 6,6. The same
can also be done with polyethylene terephthalate or other materials
having a higher melting point than the matrix material in the
multiconstituent blend, or with a mechanically blended (Taslan for
example) yarn such as illustrated in examples A, B or C of table I
above in combination with another fiber forming thermoplastic
material.
In heat-treating the fabric produced in this manner, fusion on one
side but not on the other can be achieved, resulting in a fabric
retaining a soft hand on one side but improved shape stability on
the other. Such fabrics are useful, for example, in the production
of wrinkle resistant fabrics or permanent crease-type garments, and
also may be employed in the production of garments requiring a hard
or tough exterior or surface. The fabric may be selectively heated
where a low melting fiber or yarn is combined with the
multiconstituent yarn or blended yarn to avoid fusion of the latter
if maximum utilization of the properties of the nonmulticonstituent
is desired. For example, heat may be carried out in a mold where
only the male or female side is heated while the other is cooled or
allowed to remain at a relatively lower temperature during the
short period required for fusing the other side, or the fabric may
be passed over a heated roll or series of rolls, one of which is
heated to a temperature sufficient to fuse the multiconstituent
yarn.
In the case of polyester or other yarn having a melting point
higher than the multiconstituent matrix in the fabric, it is
possible to merely heat-treat the entire fabric as mentioned before
with fusion of the multiconstituent component on one side occurring
during such heating and maintaining the hand and other physical
properties of the polyester portion of the fabric since the melt
temperature of the polyester is not reached.
The wrinkle resistance of examples A and B of table I were measured
and the results are reported in table II below. As illustrated, the
wrinkle resistance of these fabrics remarkably improved.
TABLE II ##SPC2##
Several fabric samples composed of various constructions and fiber
blends were heat-treated in accordance with the invention and the
results are reported in table III. The data therein illustrates
that highly desirable properties can be obtained by varying the
fabric construction, blend of materials and heat-treating
conditions. Thus, by incorporating selected materials and amounts
thereof, products can be tailored to exhibit the desired properties
for a given use. For example, the flammable properties of a fabric
can be improved by incorporating a nonflammable inorganic fibrous
material such as illustrated by examples 17 and 18 of table III.
These fabrics were tested in accordance with the standard Fire
Resistance of Industrial Fabrics test method AATCC 34-1952 and in
both instances were satisfactory. In another embodiment a nonwoven
fibrous structure was prepared from a 50/50 staple mixture of 70/30
nylon 6- polyester blend and asbestos fibers. The nonwoven
structure was heated to 240.degree. C. for 60 seconds to fuse the
nylon-polyester component. The fused structure had excellent
strength and did not propagate flame when subjected to the above
test method. Additional heating of the structure produced a hard
stiff material suitable for use as panelling, etc.
The products of this invention may be employed above or in
combination with other articles to form laminates or other types of
reinforced articles and products. ##SPC3## ##SPC4##
The invention may be embodied in other specific forms without
departing from the spirit or essential characteristics thereof. The
present embodiments are therefore to be considered in all respects
as illustrative and not restrictive, the scope of the invention
being indicated by the appended claims rather than by the foregoing
description, and all changes which come within the meaning and
range of equivalency of the claims are therefore intended to be
embraced therein.
* * * * *