US2777779A - Faced textile material - Google Patents
Faced textile material Download PDFInfo
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- US2777779A US2777779A US7190449A US2777779A US 2777779 A US2777779 A US 2777779A US 7190449 A US7190449 A US 7190449A US 2777779 A US2777779 A US 2777779A
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- Prior art keywords
- adhesive
- web
- gauze
- threads
- thread
- Prior art date
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Classifications
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- 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
- D04H3/12—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 filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
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- 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
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
- D04H3/045—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles for net manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/102—Woven scrim
- Y10T442/159—Including a nonwoven fabric which is not a scrim
Definitions
- This invention relates to an improvement in textile fabrics, and especially to fabrics embodying a web of Woven material having a substantial amount of tensile strength and a facing of non-woven fibers on at least one face of the woven fabric to modify the normal surface characteristics of the woven material.
- material of the character indicated may be promachinery; ducing such the material being produced.
- Fig. 1 is a more or less schematic illustration on an enlarged scale of the construction of the improved faced abn'c;
- Fig. 2 is a schematic illustration of the method and apparatus for producing the improved fabric
- Fig. 3 is a more or less schematic illustration on an enlarged scale of a part of the method and apparatus shown in Fig. 2;
- Fig. 4 is a more or less schematic illustration on an enlarged scale of a detail of construction of the woven component of the improved fabric.
- the fabric Structure shown in Fig. 1 consists of la web threads are represented at 3.
- Thermoplastic adhesive material is applied to the woven web in small discrete areas ia at alternate intersections of the Woven threads, and also the product is destined.
- the web structure shown in Fig. l may be produced by suitably beyond the doctor blade.
- the adhesive 9 is applied to the upper surface ofthe gauze web.
- the adhesive is preferably of a thermoplastic character aithough this is not essential.
- the adhesive may be permitted to dry or set or setting or drying thereof may be accelerated by any suitable means. This means, one form appear. There is some advantage in depositing the fibers on adhesive which is at least slightly tacky, the ber being thereby more or iess immediately gripped upon contact with the adhesive and held against shifting or rebounding from the carrier web.
- the adhesive may be applied to the gauze 1 and dried or partially dried as may be preferred while the gauze is traveling at a fairly high rate of speed, for example, 200 feet per minute or more and the adhesively treated gauze components of the web.
- the adhesive is preferably of fairly heavy viscosity, for example from 3500 centipoises to 9500 Centipoises or more, so that it tends to re- ⁇ main on the surface of the threads of the gauze.
- Such adhesive may be applied by propelling the gauze at a speed of around 29d feet per minute while the surface speed of the applicator roll is around 185 feet per minute in the same direction as the gauze.
- the effect is to cause the gauze to wipe across the surface of the roll to thereby scrape some of the fairly viscous adhesive from the roll.
- the gauze bearsV on the adhesive carrying roll surface particularly at the thread crossings.V Portions of the filler threads 3 ⁇ which overlie the longitudinal threads more or less project from plane of the gauze and these projecting or high portions of the cross threads 3 tend to scrape some of the adhesive from the surface of the roll. This is represented in Fig. 3 where the crosswise thread indicated at.
- the lengthwise extending threads alsopiclt up a coating of the adhesive which extends circumferentially only from about one-fourth to about one-half of the distance around the threads, but more or less continuously lengthwise thereof. rhe lengt nvise continuity of adhesive coating on the longitudinal threads may be broken for short lengths immediately behind the cross threads (with reference to the direction of travel of the gauze during the adhesive applying operation) and perhaps haphazardly at other points as indicated, due to Various causes, for example, a probable tendency to stretch or elongate the adhesive ribbons which would evidently occur asan incident to the travel of the gauze at a higher speed than the surface speed of the adhesive applicator roll.
- the adhesive free portions of the crosswise and lengthwise threads serve to retain in the fabric a substantial measure of the normal softness and flexibility of the threads which form the fabric.
- the quantity and location of adhesive in the areas 4a and 4b ⁇ may be adjusted by adjusting the relative 'speeds ofthe web and adhesive applying roll, by adjusting the circumferential extent of the contact between the web and the adhesive applying roll, and by adjusting the depth of the coating of adhesive on the applying roll.
- the ladhesive is more or less accumulated or piled up on the front or leading sides of the cross threads 3 at their points of crossing the lengthwise threads 2; lf the roll is rotated at a surface speed which is greater than that of the gauze travel, such accumulations of adhesive will be produced in back vof said portions of the cross threads.
- the fibers to form the knon-woven applique or facing 5 emanate from cotton sliversor header rolls, or from coiler cotton or any suitable lap or bat of the selected cotton or other fibers.
- lap and bat when employed to refer to a source of fibers, refer to any suitable assemblage thereof, whether or not in the forms technically known as sliver, header roll, lap, bat, etc.
- The'lap or bat of fibers is preferably non-woven, and although it may be and .usually is of self-supporting strength, it is preferably not too tightly matted or felted.
- the source of the fiber film 5 is shown as being la lap 5a of cotton, that is to. say, a non-woven the normal Y f theV same rate that the with the web 1.
- deflbering roll i3 This debat of cotton (or other) toward a divellicating or iibering roll is driven at provided with a multiplicity of teeth projecting from the normal roll surface, said teeth being operative to pull fibers from the lap 5a as the lap is fed toward the roll.
- the feed of the lap 5a toward the roll should be carefully regulated to permit the teeth'of the roll to act against only a single fiber thickness on the end of the lap, thereby to insure disintegration of the lap fiber by fiber and tc avoid the biting off-of heavy chunks which would be somewhat objectionable becausesuch chunks would interfere with the desired smoothness and softness of the final product.
- the defibering rolll is arranged in to a continuously traveling wire screen suitable relation belt 14 on which the separated fibers indicated at 5b are deposited to build up a secondary or refined bat or lap 5c of fiber.
- the thickness of the bat 5c may be controlled as desired by appropriately regulating the speed of travel of the Screen belt, by regulating the rate at which the lap 5a is fed to the roll 13, and also by appropriate selection of a starting lap 5a of predetermined thickness.
- a suction box i5 is preferably associated with theV upper reach of the screen to facilitate and more Vor less control the deposition of the fibers 5b on said screen.
- Suitable guide walls may be arranged to confine the stream of 'fibers Sb in the desired path.
- the reiined lap or bat 5c of fibers may be rolled upon itself for storage purposes and for subsequent use.
- said refined bat 5c may be fed directly into the operating zone of a second defibering roll 16 of substantially the same character as the roll 13.
- the speed at which the bat Sc is fed to the roll 16 is, of course, carefully controlled to insure operation ofthe roll 16 on substantially single liber portions of the advancing end of the bat 5c.
- Formation of the bat o'c may be so regulated that this renedbat may be fed forwardly at starting lap 5a is fed and the roll 16 will operate in a satisfactory manner to properly disintegrate thereiined bat 5c into single fiber pieces.
- this arrangement the rolling of the web 5c upon ⁇ itself may be avoided and-the process made substantially continuous from the disintegration ofthe lap 5a to the deposition of the fibers on and attachment thereof to the carrier web.
- the stream 5d of fibers produced by the roll 16 is suitably guided to the surface of the web 1 which may come directly from the drier l2 or from la supply roll 6b which would be one of the rolls produced as indicated at .6a. if the web is drawn from a supply roll such as the roll 6b, the roll is so mounted and the web is so drawn from it that the adhesive bearing side of the web ⁇ will'be ⁇ on vthe top face of the web on which the stream 5d of libers is deposited.
- rfhe deposition of the Jfiber 5d on the webv 1 may be aided by means of a suction box 17
- the web 1 now having a non-Woven appliqueor facing of fiber 5d is next guided by means of suitable guide rolls 18 around a portion of a firm but resilient calender roll lil which is supported by a rigid supp rting rollrZ.
- A'V heated steel or similar hard and rigid calendar roll 21 the calender roll'lii to press the liber and woven web tightly together, the heat of theroll ,'21 serving to soften thermoplastic adhesive in the areasV 4a and 4b so ,as to permit the fibers 5d to be ernbeddd in coop eratesV with high speed and its surface .
- the fiber is effectively bonded to the web l in the arrangement described so that there is a negligible amount of loose fiber which will dust off the finished web during handling.
- This effective bonding of the ber results mainly from the direct adhesive bonding of some of the fibers to spaced portions of the carrier web of gauze, for example at the areas 4a and at various points where the fibers cross the coatings 4b on the threads 2, and from the fact that some of the fibers which are directly adhe'- the same kind, especially after the calendering operation whereby the fibers are forced into intimate contact with each other and with the carrier web.
- the fiber lengths may Vary from as little or less than JAG of an inch to as much as one inch or more.
- the woven web is itself stabilized in respect of the positions of the threads relative to one another. This helps to maintain the woven threads in the desired uniform grid-like formation which provides an effective support for the non-woven fiber film; it also adds appreciably to the appearance of the product.
- the points of adhesive bonding of the threads of the carrier web and of the applied fiber to the carrier web the normal exibility of the Woven material is maintained, to a high degree if not in its entirety.
- the non-woven applique of bers arranged in haphazard directions as indicated in Fig. l serves as a sort of shield for the relatively harsh threads of the woven fabric, said film or facing presenting a soft, smooth surface which has important non-chafing characteristics when the material is employed as a wrapper for a sanitary napkin or other types of bandages.
- the non-woven film 5 of ber is made somewhat heavier, the material is adaptable to the making of ornamental fabrics, such as drapes, the woven thread component serving to impart adequate strengthrwhile the non-woven lrn provides a finished looking surface which may be imprinted or otherwise decorated.
- the suction box 17 By the employment of fairly strong suction in the suction box 17, a considerable amount of the fiber may be this may be highly desirable.
- the adhesive content o the surface of the threads of the gauze web with but little, if any, penetration of the threads of the gauze.
- thermoplastic iibers will provide bonds between at least some of the crossing threads of the gauze and also spaced bonds between the gauze and the ber layer appliedto the face of the gauze when the gauze and facing thereon are subjected to the heat of the calender which will reactivate said thermoplastic fibers to the ame end that said heat reactivates thermoplastic applied to the gauze as hereinbefore described.
- thermoplastic adhesive instead of einpioying heat and pressure to reactivate the thermoplastic adhesive, or thermoplastic fibers spun into the threads of the gauze, we may employ either heat or pressure alone, or solvents of the thermoplastic material.
- the gauze component may consist of woven gauze having a thread count within the range of 18 x 14 down to 4 x 4.
- the adhesive may be a suitably plasticized polyvinyl acetate in ernulsionform preferably embodying some solvent, said adhesive being thermoplastic in character.
- This adhesive may be applied at the rate of about 2 grams per square yard of 18 X 8 sch mannitol, and it may easily be dried to the extent desired within a short length of travel, say from 5 to 35 feet, by passing a current of air heated to around 399 F. over the web in the direction opposite to the direction of travel of the web, depending somewhat on the rate of travel of the web.
- This adhesive has the property of remaining on the surface of the gauze threads with but little, if any, penetration thereof and, upon drying remains heat softenable or thermoplastic.
- the said adhesive is waterproof and permanently flexible so that there is no stiffening with age whereby shelf-life of the sanitary napkins is not affected.
- This adhesive has the advantage of softening and becomingl exceptionally tacky at temperatures around to 185 F. which is sufficiently above body temperature to avoid softening incident to the heat of the body; it is colorless, odorless and non-irritating and its melting temperature is not high enough to cause scorching or" the gauze when the of individualpreferences.
- the amount of adhesive applied may, of course, be decreased or Yincreased from that 'set forth.
- Attachment of the fibers to the thread web as aforesaid is due to engagement of the bers with adhesive bearing portions vof thethreads and also to natural tendencies for bers to cling to threads, such tendency being increased by the calendering of the material whereby the ber layer is Y pressed into ⁇ intimate engagement with the Ythread fabric.
- the heat imparted to the adhesive, and the heat imparted to the gauze in the drying operation has some effect in maintaining the adhesive inY such uncured condition that the adhesive sur-V faces are active during the passage of the gauze through the ber depositing zone of the divellicatorl, especially if the arrangement is such that the distance between the Y drying chamber and divellicator is short enough to prevent open air drying of the adhesive and cooling thereof to setting temperature'before it reaches said ber-depositing zone.
- @The-rolls 19 and 21 may be 'urged together under a forceranging up to around 770 pounds per linealinch of the rolls.
- a force ot' about 120 pounds per lineal'inch producesvvery satisfactory results in connection with a cotton fiber facing of from 4 toV 6 grams p er square yard andadhesive of the polyvinyl acetate emulsion form described and applied at the said rate of 2 grams per square yard.
- equivalent utility we refer to the usefulness ofthe woven material for a given purpose where its softness, smoothness, and similar characteristics are itu- ⁇ portant considerations.
- Y Y Y For example, .in current, actual practice, a well known brand of sanitary napkins khas a Ywrapper made ⁇ of;
- the facing ber may lconsist of relatively inexpensive short length bers, and other added production costs, perrunit of the'faced material is less than the value of the thread saved and other costs saved in the production of the open mesh gauze employed in the facedV material.
- the ber may be such' as to give a-high sheen to the materialV and it may be relatively'impermeable so as to facilitate surface ornamentation by printing, painting or other'treatment. These and other characteristics are easily attained .byA'appropriate-ber selection, appropriate ber orientation on the gauze, appropriate carrier' web selection, adjustment of the amount of ber applied, adjustment of the Vamount andV kind of adhesive employed and the calendering pressure.Y None of 'these changes require any extensive change in the apparatus.
- Textile fabric comprising interlaced threads, and adhesive bonding intersecting thread portions to each other Where thread adhesive, preserve the normal softness of the said intermediate thread portions, whereby the normal softness of the fabric before stabilization thereof as aforesaid is preserved to a high degree.
- a thread web having thread portions which intersect each other in spaced relation to provide a web havfor laminating the web to other material.
- a thread web having thread portions which interweb, a majority of said thread portions which extend in one general direction having portions of their lengths intermediate said bonded intersections substantially free of adhesive, and a majority of other thread portions which extend in a direction transintermediate said bonded intersections but discontinuously along their lengths, so as to provide adhesive free lengths on said other thread portions, said adhesive free lengths serving to retain to a substantial degree in the web, the normal softness of said thread portions before stabilization of the web as aforesaid, and a layer of bers attached to said web by said adhesive, some of said bers being adhered sect eachother in lspaced relation to provide a web hav- Y ing the :openness of a piece of woven gauze having,Y aV
- a ⁇ thread web having thread portions which intersect each other in spaced relation to provide a Web having the openness of a piece of woven gauze having a thread count construction within the range of about 18x 14 to about 4 x 4, and having substantially uniformly distributed thread intersections adhesively bonded by -adhesive which is substantially'coniined to one face of the web, some of the thread portions intermediate said thread intersections being substantially free of adhesive.
Description
I Jan 15, 1957 K. J. HAFeWooD ET AL 2,777,779
FACED TEXTILE MATERIAL Filed Jan. 2l, 1949 75 Vaca um.
United States Patent there Patented Jan. i5, w57
2,777,779 FACED TEXTILE MATERAL Kenneth J. Harwood, Neenah, and Harvey J. Le Dain, Appleton, Wis., assignors, by mesne assignments, to Kimberly-Clark Corporation, a corporation of Delaware Application January 21, 1949, Serial No. 71,904 12 Claims. (Cl. 117-25) This invention relates to an improvement in textile fabrics, and especially to fabrics embodying a web of Woven material having a substantial amount of tensile strength and a facing of non-woven fibers on at least one face of the woven fabric to modify the normal surface characteristics of the woven material.
Fabrics of this character range of uses,
materials; to provide faced fabric of the character indicated which Will afford the tensile strength of Woven textile material such component parts.
Other objects of the invention whereby material of the character indicated may be promachinery; ducing such the material being produced.
Other objects and advantages of the invention will be understood by reference to and accompanying drawing in which there is schematically illustrated the structure of the improved faced material and the method of producing it.
ln the drawings:
Fig. 1 is a more or less schematic illustration on an enlarged scale of the construction of the improved faced abn'c;
Fig. 2 is a schematic illustration of the method and apparatus for producing the improved fabric;
Fig. 3 is a more or less schematic illustration on an enlarged scale of a part of the method and apparatus shown in Fig. 2; and
Fig. 4 is a more or less schematic illustration on an enlarged scale of a detail of construction of the woven component of the improved fabric.
The fabric Structure shown in Fig. 1 consists of la web threads are represented at 3.
Thermoplastic adhesive material is applied to the woven web in small discrete areas ia at alternate intersections of the Woven threads, and also the product is destined.
The web structure shown in Fig. l may be produced by suitably beyond the doctor blade. By this arrangement, the adhesive 9 is applied to the upper surface ofthe gauze web. For many purposes, the adhesive is preferably of a thermoplastic character aithough this is not essential.
The adhesive, Whatever its character, may be permitted to dry or set or setting or drying thereof may be accelerated by any suitable means. This means, one form appear. There is some advantage in depositing the fibers on adhesive which is at least slightly tacky, the ber being thereby more or iess immediately gripped upon contact with the adhesive and held against shifting or rebounding from the carrier web.
The adhesive may be applied to the gauze 1 and dried or partially dried as may be preferred while the gauze is traveling at a fairly high rate of speed, for example, 200 feet per minute or more and the adhesively treated gauze components of the web. For example, the adhesive is preferably of fairly heavy viscosity, for example from 3500 centipoises to 9500 Centipoises or more, so that it tends to re-` main on the surface of the threads of the gauze. Such adhesive may be applied by propelling the gauze at a speed of around 29d feet per minute while the surface speed of the applicator roll is around 185 feet per minute in the same direction as the gauze. When the gauze web and roll are driven in this relationship, i. e., with a Speed differential of about 7%, the effect is to cause the gauze to wipe across the surface of the roll to thereby scrape some of the fairly viscous adhesive from the roll. As indicated in Fig. 3, the gauze bearsV on the adhesive carrying roll surface particularly at the thread crossings.V Portions of the filler threads 3 `which overlie the longitudinal threads more or less project from plane of the gauze and these projecting or high portions of the cross threads 3 tend to scrape some of the adhesive from the surface of the roll. This is represented in Fig. 3 where the crosswise thread indicated at. 3a is illustrated as having a small amount of adhesive piled up in `front of the thread, the roll surface being substantially scraped clean of adhesive for a short portion of its circumference as indicated Vat Sa- As the thread 3a reaches the successive positions 3b to 3f inclusive, the adhesive accumulation will gradually increase until there is aquantity sufcient to constitute one of the areas da,
the cleaned roll surface 8a being correspondingly en-k larged as indicated at Sb. Hence, by the time the woven web leaves the roll 8 it will have accumulated small blobs 4a Vof adhesive material at alternate intersections of the threads as indicated in Fig. l, the crosswise threads 3 remaining substantially free of adhesive intermediate said bonded intersections as illustrated.
The lengthwise extending threads alsopiclt up a coating of the adhesive which extends circumferentially only from about one-fourth to about one-half of the distance around the threads, but more or less continuously lengthwise thereof. rhe lengt nvise continuity of adhesive coating on the longitudinal threads may be broken for short lengths immediately behind the cross threads (with reference to the direction of travel of the gauze during the adhesive applying operation) and perhaps haphazardly at other points as indicated, due to Various causes, for example, a probable tendency to stretch or elongate the adhesive ribbons which would evidently occur asan incident to the travel of the gauze at a higher speed than the surface speed of the adhesive applicator roll. The adhesive free portions of the crosswise and lengthwise threads serve to retain in the fabric a substantial measure of the normal softness and flexibility of the threads which form the fabric.
The quantity and location of adhesive in the areas 4a and 4b `may be adjusted by adjusting the relative 'speeds ofthe web and adhesive applying roll, by adjusting the circumferential extent of the contact between the web and the adhesive applying roll, and by adjusting the depth of the coating of adhesive on the applying roll. In the arrangement shown and described, the ladhesive is more or less accumulated or piled up on the front or leading sides of the cross threads 3 at their points of crossing the lengthwise threads 2; lf the roll is rotated at a surface speed which is greater than that of the gauze travel, such accumulations of adhesive will be produced in back vof said portions of the cross threads.
The fibers to form the knon-woven applique or facing 5 emanate from cotton sliversor header rolls, or from coiler cotton or any suitable lap or bat of the selected cotton or other fibers. Hence, in the following description and in thel claims, the terms lap and bat, when employed to refer to a source of fibers, refer to any suitable assemblage thereof, whether or not in the forms technically known as sliver, header roll, lap, bat, etc. The'lap or bat of fibers is preferably non-woven, and although it may be and .usually is of self-supporting strength, it is preferably not too tightly matted or felted.
'in Fig. 2, the source of the fiber film 5 is shown as being la lap 5a of cotton, that is to. say, a non-woven the normal Y f theV same rate that the with the web 1.
fiber which is suitably fed deflbering roll i3. This debat of cotton (or other) toward a divellicating or iibering roll is driven at provided with a multiplicity of teeth projecting from the normal roll surface, said teeth being operative to pull fibers from the lap 5a as the lap is fed toward the roll. The feed of the lap 5a toward the roll should be carefully regulated to permit the teeth'of the roll to act against only a single fiber thickness on the end of the lap, thereby to insure disintegration of the lap fiber by fiber and tc avoid the biting off-of heavy chunks which would be somewhat objectionable becausesuch chunks would interfere with the desired smoothness and softness of the final product. Y
The defibering rolll is arranged in to a continuously traveling wire screen suitable relation belt 14 on which the separated fibers indicated at 5b are deposited to build up a secondary or refined bat or lap 5c of fiber. The thickness of the bat 5c may be controlled as desired by appropriately regulating the speed of travel of the Screen belt, by regulating the rate at which the lap 5a is fed to the roll 13, and also by appropriate selection of a starting lap 5a of predetermined thickness.
A suction box i5 is preferably associated with theV upper reach of the screen to facilitate and more Vor less control the deposition of the fibers 5b on said screen. Suitable guide walls may be arranged to confine the stream of 'fibers Sb in the desired path.
The reiined lap or bat 5c of fibers may be rolled upon itself for storage purposes and for subsequent use. However, said refined bat 5c may be fed directly into the operating zone of a second defibering roll 16 of substantially the same character as the roll 13. The speed at which the bat Sc is fed to the roll 16 is, of course, carefully controlled to insure operation ofthe roll 16 on substantially single liber portions of the advancing end of the bat 5c. Formation of the bat o'c may be so regulated that this renedbat may be fed forwardly at starting lap 5a is fed and the roll 16 will operate in a satisfactory manner to properly disintegrate thereiined bat 5c into single fiber pieces. yBy this arrangement the rolling of the web 5c upon `itself may be avoided and-the process made substantially continuous from the disintegration ofthe lap 5a to the deposition of the fibers on and attachment thereof to the carrier web.
This subjection of the fiber material to successive deiibering operations results in very effective kuntangling and separation of the fibers so that the deposition of yliber on the Vcarrier web may easily be confined vto a frlm as light as 1.5 grams per square yard, the fiber being Aquite uniformly distributed and deposited, usually in a haphazard directional arrarngement,V althoughby means o certain controls the directional arrangement vmay be more or less predetermined.
The stream 5d of fibers produced by the roll 16 is suitably guided to the surface of the web 1 which may come directly from the drier l2 or from la supply roll 6b which would be one of the rolls produced as indicated at .6a. if the web is drawn from a supply roll such as the roll 6b, the roll is so mounted and the web is so drawn from it that the adhesive bearing side of the web` will'be `on vthe top face of the web on which the stream 5d of libers is deposited. rfhe deposition of the Jfiber 5d on the webv 1 may be aided by means of a suction box 17 The web 1 now having a non-Woven appliqueor facing of fiber 5d is next guided by means of suitable guide rolls 18 around a portion of a firm but resilient calender roll lil which is supported by a rigid supp rting rollrZ.
A'V heated steel or similar hard and rigid calendar roll 21 the calender roll'lii to press the liber and woven web tightly together, the heat of theroll ,'21 serving to soften thermoplastic adhesive in the areasV 4a and 4b so ,as to permit the fibers 5d to be ernbeddd in coop eratesV with high speed and its surface .is
associated pressed into each other at their crossings and the threads are more or less attened approximately as represented at 22 in Fig. 4. This iiattening and embedding of the threads in each other serves to eliminate to a considerable extent the prominences usually present in Woven material at the crossings of the interwoven threads. To a lesser extent the entire lengths of the threads are also slightly attened. Flattening of the crossing thread portions and flattening of the threads throughout their lengths, probably serves to increase the flexibility of the fabric since the thickness of the material is reduced with a corresponding increase in bendability. The employment of the more or less resilient, cotton-constructed roll 19, avoids cutting of the threads of the gauze at their crossings when subjected to the indicated calenden'ng operation.
The fiber is effectively bonded to the web l in the arrangement described so that there is a negligible amount of loose fiber which will dust off the finished web during handling. This effective bonding of the ber results mainly from the direct adhesive bonding of some of the fibers to spaced portions of the carrier web of gauze, for example at the areas 4a and at various points where the fibers cross the coatings 4b on the threads 2, and from the fact that some of the fibers which are directly adhe'- the same kind, especially after the calendering operation whereby the fibers are forced into intimate contact with each other and with the carrier web. For the reasons indicated, even the shortest fibers are effectively retained in the applique, it being understood that the fiber lengths may Vary from as little or less than JAG of an inch to as much as one inch or more.
By causing the threads of the Woven fabric to be adhesively bonded together at alternate crossings thereof as shown at 4a, the woven web is itself stabilized in respect of the positions of the threads relative to one another. This helps to maintain the woven threads in the desired uniform grid-like formation which provides an effective support for the non-woven fiber film; it also adds appreciably to the appearance of the product. By spacing the points of adhesive bonding of the threads of the carrier web and of the applied fiber to the carrier web, the normal exibility of the Woven material is maintained, to a high degree if not in its entirety.
stir'fen threads or the gauze.
The non-woven applique of bers arranged in haphazard directions as indicated in Fig. l serves as a sort of shield for the relatively harsh threads of the woven fabric, said film or facing presenting a soft, smooth surface which has important non-chafing characteristics when the material is employed as a wrapper for a sanitary napkin or other types of bandages. When the non-woven film 5 of ber is made somewhat heavier, the material is adaptable to the making of ornamental fabrics, such as drapes, the woven thread component serving to impart adequate strengthrwhile the non-woven lrn provides a finished looking surface which may be imprinted or otherwise decorated. By the employment of fairly strong suction in the suction box 17, a considerable amount of the fiber may be this may be highly desirable.
Instead of the indicated type of divellicating or deliber-- supply lap apart into its component bers and to deposit such separated fibers on the carrier web.
For many purposes it is preferable that the adhesive content o the surface of the threads of the gauze web with but little, if any, penetration of the threads of the gauze. By the employment of a permanently flexible adhesive which will remain on the surface of the threads, most of the Generally, such penetrating adhesives have a tendency to harden or stiten the fabric-this is somewhat dependent on the characteristics of the particular adhesive employed.
For some purposes, we may avoid the application of Such thermoplastic iibers will provide bonds between at least some of the crossing threads of the gauze and also spaced bonds between the gauze and the ber layer appliedto the face of the gauze when the gauze and facing thereon are subjected to the heat of the calender which will reactivate said thermoplastic fibers to the ame end that said heat reactivates thermoplastic applied to the gauze as hereinbefore described.
instead of einpioying heat and pressure to reactivate the thermoplastic adhesive, or thermoplastic fibers spun into the threads of the gauze, we may employ either heat or pressure alone, or solvents of the thermoplastic material.
When the described fabric is made to be used in the wrapper of a sanitary napkin, the gauze component may consist of woven gauze having a thread count within the range of 18 x 14 down to 4 x 4. The adhesive may be a suitably plasticized polyvinyl acetate in ernulsionform preferably embodying some solvent, said adhesive being thermoplastic in character. This adhesive may be applied at the rate of about 2 grams per square yard of 18 X 8 ganze by the method described, and it may easily be dried to the extent desired within a short length of travel, say from 5 to 35 feet, by passing a current of air heated to around 399 F. over the web in the direction opposite to the direction of travel of the web, depending somewhat on the rate of travel of the web. This adhesive has the property of remaining on the surface of the gauze threads with but little, if any, penetration thereof and, upon drying remains heat softenable or thermoplastic. The said adhesive is waterproof and permanently flexible so that there is no stiffening with age whereby shelf-life of the sanitary napkins is not affected. This adhesive has the advantage of softening and becomingl exceptionally tacky at temperatures around to 185 F. which is sufficiently above body temperature to avoid softening incident to the heat of the body; it is colorless, odorless and non-irritating and its melting temperature is not high enough to cause scorching or" the gauze when the of individualpreferences.
Vadhesive thereon,
gauze. and ber iilmarepass'ed through thecalenderl and Y heated to reactivatet-headhesiveand so as to causeemb'e'dment of 4the 'fibers therein. The amount of adhesive applied may, of course, be decreased or Yincreased from that 'set forth.
k The 'amount of Yadhesive may vary considerably.V Our experience indicatesthat successful sanitary napkin wrappers maybe made with 18 XIS gauze having adhesive material applied thereto ,at a rate within the range of ..3 to grams Vper square yard `:and'with nonwoven Jfiber applied at a rate within the rangeof l.5 to 8 grams per square yard. The .optimum is, at least in part, a matter Our present preference is adhesive atthe rate Vofabout 2 gramsV per square yard Vand ber Vat the rate -of from 4 to 6 grams persquare yard lalthough as little as 1.5 grams of ber uniformly-'dis-Y tributed is sucient toeliminate the normal harsh feel. of
Y A the gauze.
y When the Weight of the ber layer is within the range of 155 to 6 grams per square yard, a large proportion of thebers, Vprobably a major proportion thereof, directly `engage theV threads of the gauze web and become directly attachedthereto. This'resultsin very secure attachment ofthe ber layer as an entirety and prevents displace- Y ment of the ber layer from the thread web by scufring or rubbing action in the normal use of asanitary napkin embodying a wrapper of the described construction, the ber layer being on the outside of the wrapper so as to be directly subjected to such rubbing action. Attachment of the fibers to the thread web as aforesaid is due to engagement of the bers with adhesive bearing portions vof thethreads and also to natural tendencies for bers to cling to threads, such tendency being increased by the calendering of the material whereby the ber layer is Y pressed into `intimate engagement with the Ythread fabric.
; to the bers which come into engagement with such areas. The adhesive content ofV said areas will be reactivated by the heat (and pressure) of said calendering rolls so'that the Vinitial embedment of the bers in said adhesive will be deepened and improved by the calender. When the described polyvinyl acetate thermoplastic adhesive is used, it is possible that the heat imparted to the adhesive, and the heat imparted to the gauze in the drying operation, has some effect in maintaining the adhesive inY such uncured condition that the adhesive sur-V faces are active during the passage of the gauze through the ber depositing zone of the divellicatorl, especially if the arrangement is such that the distance between the Y drying chamber and divellicator is short enough to prevent open air drying of the adhesive and cooling thereof to setting temperature'before it reaches said ber-depositing zone. Y Y
@The-rolls 19 and 21 may be 'urged together under a forceranging up to around 770 pounds per linealinch of the rolls. A force ot' about 120 pounds per lineal'inch producesvvery satisfactory results in connection with a cotton fiber facing of from 4 toV 6 grams p er square yard andadhesive of the polyvinyl acetate emulsion form described and applied at the said rate of 2 grams per square yard. Y
A-length of material prepared according'to the foregoing explanation'can'be produced atrless cost than a 'e corresponding length of Woven materialof equivalent utility. By equivalent utilitywe refer to the usefulness ofthe woven material for a given purpose where its softness, smoothness, and similar characteristics are itu-` portant considerations. Y Y Y For example, .in current, actual practice, a well known brand of sanitary napkins khas a Ywrapper made` of;
and also makes the material very difficult to `handle in automatic napkin-making machinery; because of its tend- 'Y ency to irregularity of thread arrangement and hence its relative unsightliness, and other reasons.
The material herein described, embodyingopenmesh, 1S X8 gauze with a light applique or facing of bers, when used for wrapping a sanitary'napkin, has been found to be very satisfactory in respect of all of the above-mentioned deficiencies of plain open mesh gauzeY and to have certain advantages of softness, smoothness,
and better appearance over the usual plainjrelatively The faced material isrnevertheclosely woven material,
closely-woven wrapper. less less costly than the said mainly because the faced material embodies asubstanj tially reduced amount of the costly thread required for the-production' of gauze. The facing ber may lconsist of relatively inexpensive short length bers, and other added production costs, perrunit of the'faced material is less than the value of the thread saved and other costs saved in the production of the open mesh gauze employed in the facedV material. Hence, there is an importantnet saving in'zthe cost of production-of the improved, faced Vmaterial ascompare'd with more closely woven gauze Vwhich hasrheretofore been required for sanitary napkiny productionV purposes.
It shouldibe understood that considerable variation is possible in respect ofthe quantities and kinds of adhesive and ber employed in producing the faced material. Variations of Vthese quantities serve toV alter the characteristics of the product. unitiofmaterialV produced tend to impair permeability of the material while increasing the cushion characteristicn tity as to provide a high capacity for duid absorption.` Y
For decorative purposes, the ber may be such' as to give a-high sheen to the materialV and it may be relatively'impermeable so as to facilitate surface ornamentation by printing, painting or other'treatment. These and other characteristics are easily attained .byA'appropriate-ber selection, appropriate ber orientation on the gauze, appropriate carrier' web selection, adjustment of the amount of ber applied, adjustment of the Vamount andV kind of adhesive employed and the calendering pressure.Y None of 'these changes require any extensive change in the apparatus. 'Y l Y it will be apparent that the above ldescribed method of applying adhesive to woven gauze material to Vstabilize the positions of 'the threads in such material, may also be employed for stabilizing thread positions in knitted material which also embodies projections or knuckles Y where thread portions cross one another. .In the appended claims, the word interlaced isA used to referto any fabric construction in which threadsare so arranged that some 'portions Athereof cross other portions'and form projections or lknuckles` where such thread portions cross the vcost of which, ltogetl'ier with the cost of the adhesive employed Larger quantities of berper Y one another, the most common processes by which fabrics are so formed being knitting and weaving.
Various other changes in the described product and in the method of making the same may be made while retaining the principles of the invention.
We claim:
before stabilization thereof as aforesaid, is preserved to a high degree.
2. Textile fabric comprising interlaced threads, and
adhesive bonding intersecting thread portions to each on surface areas of said intersecting thread portions on the face of the fabric on which one of the thread portions of each pair of intersecting thread portions crosses over its intersecting thread portion, the surface areas of said intersecting thread porcross-over threads on opposite sides sections being also substantially free of said adhesive, whereby adhesive-hardening of the fabric is avoided to a substantial degree.
3. Textile fabric comprising interlaced threads, and adhesive bonding intersecting thread portions to each other Where thread adhesive, preserve the normal softness of the said intermediate thread portions, whereby the normal softness of the fabric before stabilization thereof as aforesaid is preserved to a high degree.
intersecting thread portions being flattened so as pressed together and to reduce the thickness of said intersectenable said thin layer of intersections as amarre woven layer of bers attached to a face of the fabric, said ber layer having a web, and a nonwoven layer of fibers attached to said adhesive bearing face of said web, the Weight and density of said layer of fibers being so low that permeability of the Wrapping material is not signiicantly impaired and such that there is a paucity of fibers in relation to the area of the web so that a large proportion of the fibers are in direct engagement with and attachment to said web so as to provide effective resistance to displacement of the fiber layer from said web, said fiber layer being operative notwithstanding its said light weight and density to provide signilicant shielding over the threads of said Web and the intersections thereof to impart smoothness to said face of said web.
8. A thread web having thread portions which intersect each other in spaced relation to provide a web havfor laminating the web to other material.
9. A thread web having thread portions which interweb, a majority of said thread portions which extend in one general direction having portions of their lengths intermediate said bonded intersections substantially free of adhesive, and a majority of other thread portions which extend in a direction transintermediate said bonded intersections but discontinuously along their lengths, so as to provide adhesive free lengths on said other thread portions, said adhesive free lengths serving to retain to a substantial degree in the web, the normal softness of said thread portions before stabilization of the web as aforesaid, and a layer of bers attached to said web by said adhesive, some of said bers being adhered sect eachother in lspaced relation to provide a web hav- Y ing the :openness of a piece of woven gauze having,Y aV
thread count construction within fthe range of about 18 x V'14, to about 4 xV 4, and vadhesive bonding atleast some of said 4intersecting thread portionsjto each other at their intersections to stabilize Athe 'positions of said thread portions inthe web, Asaidfadhesive being applied tothe web 'at arate'which is equivalentto the application of adhesive within therange of about .3 to 5 grams per square yard `of woven gauzehaving athr'ead count construction of Y18er 8, a majority of said thread portions whichextend `in one general direction having portions of their lengths Yintermediate said bonded intersections substantially-freeof adhesive, 'and a majority of other thread portions which yextend in a direction transverse kto said Y general Idirection having adhesive thereon intermediate said bonded intersections Ybut discontinuously along their I lengths, so as Ato provide adhesive free lengths kon said other thread portions, said adhesive free iengths serving to retain `to a lsubstantial degree in the web, the normal softness of said thread'portions before stabilization of the web as aforesaid,V and a layer of bers attached to said web by said adhesive, some of said bers'being adhered 'to spaced thread portions to thereby further stabilize the web, said ber layer having a basis Weight within the range of; about 11/2 grams to 6 Vgrams per square yard of Y the web.
11;V A `thread web having thread portions which intersect each other in spaced relation to provide a Web having the openness of a piece of woven gauze having a thread count construction within the range of about 18x 14 to about 4 x 4, and having substantially uniformly distributed thread intersections adhesively bonded by -adhesive which is substantially'coniined to one face of the web, some of the thread portions intermediate said thread intersections being substantially free of adhesive.
12. A thread web having thread portions which intersect each-otherin spaced relation to provide a web having Vthe openness of a piece of woven gauze having a thread count construction within the range of about 1-8 x 14 to'about 4 x4, andhaving substantially uniformly distrihutedthread intersectionsadhesively bonded by adhesive which is substantially conned'to one Sface of the References .Cited in the le of this patent UNITED STATES PATENTS V371,913 Archer Oct. 25, 1887 `574,332 Johnston Dec. 29, 1896 998,952 Boone July 25, 1911 1,284,922 Y OConnell Nov. 12 1918 i 1,391,932 Beckwith et al. ,Sept. 27, 19,21 Y
1,861,003 yFoster May 31, 1932 Y 1,887,745 Wilkinson Nov.15, 1932 1,946,784 Elliott Feb. 13, 1934Y 2,013,812 VVSupligeau et al Sept. 10, 1935 ,t .2,050,156 7 Borghetty 'Aug.' 4,' 1936 2,057,671 Dreyfus Oct. 20, 1936y 2,086,592 Williams July 13, 1937 2,196,655 Y Borghetty Apr..9, 1940 2,232,647 Zirkrnan Feb; 18, 1941 2,266,761 Jackson et al.v Dec. 23, 1941 `2,281,830 Copernan MayY 5, 1942Y 2,294,898 Fourness et al Sept. 8, 1942 2,324,787 1 Lundgren Julykzo, 1943 2,332,221 Yl-Iarshberger Oct; 19, 1,943Y 2,362,786 Williams Nov. 14, .1944 2,384,771 YRyan Sept. 11, 1945 2,395,217 Ford et al. Feb.V 19, 1946 2,425,235 Y Ferrante ,Aug.V 5, 1947 2,434,709 Matthews f Jan. 20, 1948, 2,444,115 Reed et al June 29, 1948 v 2,478,148 Y' Wilson etal. `Aug.,2, 1949 2,491,454 Nute Dec. 13, 1949: 2,564,689 Harwoodet al Aug. 21, 1951 2,567,327 VEwing Sept. 11, 1951 2,568,144 Cremer et'al .Sept. 18, 1951 A FOREIGN PATENTS 12,514 Great Britain of 1910 588,447 Great Britain 'May22,1947`
Claims (1)
1. TEXTILE FABRIC COMPRISING INTERLACED THREADS, AND ADHESIVE BONDING INTERSECTING THREAD PORTIONS TO EACH OTHER TO STABILIZE THE THREAD POSITIONS IN THE FABRIC, PORTIONS OF SOME OF THE THREADS INTERMEDIATE SAID INTERSECTIONS BEING SUBSTANTIALLY FREE OF ADHESIVE SO AS TO PRESERVE THE NORMAL SOFTNESS OF SAID INTERMEDIATE THREAD PORTIONS WHEREBY THE NORMAL SOFTNESS OF THE FABRIC BEFORE STABILIZATION THEROF AS AFORESAID, IS PRESERVED TO A HIGH DEGREE.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US7190449 US2777779A (en) | 1949-01-21 | 1949-01-21 | Faced textile material |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US7190449 US2777779A (en) | 1949-01-21 | 1949-01-21 | Faced textile material |
US96006A US2719337A (en) | 1949-05-28 | 1949-05-28 | Method of making non-woven fabric |
GB24118/49A GB677545A (en) | 1949-09-20 | 1949-09-20 | A method and apparatus for making cloth embodying randomly arranged fibers |
US298144A US2726423A (en) | 1949-05-28 | 1952-07-10 | Apparatus for making textile fabric embodying nonwoven fibers |
Publications (1)
Publication Number | Publication Date |
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US2777779A true US2777779A (en) | 1957-01-15 |
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Family Applications (1)
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US2902037A (en) * | 1955-05-25 | 1959-09-01 | Kimberly Clark Co | Sanitary napkin |
US3040740A (en) * | 1957-11-20 | 1962-06-26 | San Francisco Res Corp | Prefabricated pad for surgical casts and the like and method for manufacturing the same |
US3110609A (en) * | 1959-04-30 | 1963-11-12 | Kimberly Clark Co | Cellulosic product |
US3132984A (en) * | 1954-10-07 | 1964-05-12 | Johnson & Johnson | Process of making a surgical dressing |
US3140973A (en) * | 1961-06-19 | 1964-07-14 | Courcelle St De | Fourdrinier wires for paper machines |
US3141810A (en) * | 1961-05-31 | 1964-07-21 | Deering Milliken Res Corp | Novel fabric and process |
US4255227A (en) * | 1980-01-23 | 1981-03-10 | Chromatex, Inc. | Apparatus for forming laminated fabrics |
US4439391A (en) * | 1979-06-26 | 1984-03-27 | International Paper Company | Polymeric sheets |
WO1997006946A2 (en) * | 1995-08-21 | 1997-02-27 | Delalott Corporation | Composite ravel-free needlework fabric and method of producing same |
US5857497A (en) * | 1985-08-05 | 1999-01-12 | Wangner Systems Corporation | Woven multilayer papermaking fabric having increased stability and permeability |
US5912067A (en) * | 1997-03-18 | 1999-06-15 | Astral International S.A. | Fabric particularly for mattresses and covers |
US6174412B1 (en) | 1998-03-02 | 2001-01-16 | Purely Cotton, Inc. | Cotton linter tissue products and method for preparing same |
US20070037463A1 (en) * | 2005-08-12 | 2007-02-15 | Kaylor Philip S | Fiber batt having a separator layer |
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US3132984A (en) * | 1954-10-07 | 1964-05-12 | Johnson & Johnson | Process of making a surgical dressing |
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