THERMAL NONWOVEN FABRIC

THERMOMATERIAU NON TISSE

English Abstract

The invention relates to a thermal nonwoven fabric consisting
of a microfilament nonwoven fabric having a weight of 60 to
300 g/m2 and a resistance to tearing > 150 N. The nonwoven
fabric consists of melt-spun, drafted endless filaments that
consist of several components and are directly placed to form
a nonwoven, whereby the titre amounts to 1.5 to 5 dtex. After
optional pre-bonding, at least 80 % of the endless filaments
that consist of several components are split to form
micro-endless filaments having a titre of 0.1 to 1.0 dtex and
are bonded.

French Abstract

L'invention concerne un thermomatériau non tissé constitué par un matériau non tissé de microfilaments, d'un grammage de 60 à 300 g/m<2> et d'une résistance au déchirement > 150 N, caractérisé en ce que le matériau non tissé est constitué par des filaments continus multicomposants de titre 1, 5 à 5 dtex, filés à fusion, étirés et directement déposés pour former une toison, et en ce que les filaments continus multicomposants sont clivés, éventuellement après pré-consolidation, pour former au moins 80 % de microfilaments continus de titre 0,1 à 0,8 dtex et sont ensuite consolidés.

Claims

CLAIMS:
1. Thermofleece for heat insulation consisting of a microfilament nonwoven
with basis
weights of 60-300 g/m2 and a breaking strength >150 N, whereby the nonwoven
consists of
meltspun, aerodynamically stretched multicomponent endless filaments
immediately laid down in a
fleece and having a titre of 1.5-5 dtex and at least 80% of the multicomponent
endless filaments
being split by high pressure fluid jets into micro endless filaments with a
titre of 0.1-1.0 dtex and
consolidated, wherein the thermofleece has an isotropic filament distribution
in the fleece.
2. Thermofleece according to claim 1, characterized in that the multicomponent
endless
filament is a bicomponent endless filament of two incompatible polymers.
3. Thermofleece according to one of claims 1 to 2, characterized in that the
multicomponent
endless filaments have a cross-section with orange-type multisegment
structure, whereby the
segments alternatingly respectively include one of the two incompatible
polymers, or have a
side-by-side structure.
4. Thermofleece according to claim 3, characterized in that two sides of the
thermofleece
material have a different segment structure.
5. Thermofleece according to claim 2, characterized in that at least one of
the incompatible
polymers forming the multicomponent endless filament includes an additive.
6. Thermofleece according to claim 5, wherein the additive is color pigments,
permanently
active antistatics, fungicides, bactericides, acaricides or additives
influencing the hydrophilic or
hydrophobic properties added in amounts of up to 10% by weight.
7. Process for the manufacture of a thermofleece for heat insulation
characterized in that the
multicomponent endless filaments are spun from a melt, stretched and
immediately laid down in a
fleece, and the nonwoven is consolidated by high pressure fluid jets, as well
as simultaneously split
into micro endless filaments with a titre of 0.1-1.0 dtex, and a degree of
splitting of >80%.
8. Process according to claim 7 further comprising the step of a
preconsolidation of the
filaments.
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9. Process according to claim 8, characterized in that the splitting of the
multicomponent
endless filaments is carried out such that the preconsolidated nonwoven is
impacted at least once
from each side by high pressure fluid jets.
10. Process according to any one of claims 7 to 9, characterized in that the
dyeing of the
multicomponent endless filaments is carried out by spin coloring.
11. Process according to any one of claims 7 to 10, characterized in that two
spinning beams are
used of which one produces multicomponent endless filaments with a pie segment
structure and the
other produces those with a side-by-side segment structure.
12. Thermofleece according to any one of claims 1 to 5, characterized in that
it is used for the
manufacture of inner liner materials.
13. Thermofleece according to any one of claims 1 to 5, characterized in that
it is used for the
manufacture of upper materials.
14. Thermofleece according to any one of claims 1 to 5, characterized in that
it is used for the
manufacture of inner pockets.
15. Thermofleece according to any one of claims 1 to 5, characterized in that
it is used for the
manufacture of wadding.
16. Thermofleece according to any one of claims 1 to 5, characterized in that
it is used for the
manufacture of padding.

Description

CA 02395462 2007-09-26
THERMAL NONWOVEN FABRIC
DESCRIPTION
The invention relates to a thermofleece consisting of a microfilament nonwoven
with
surface weights of 60-300 g/mZ and a tear resistance > 150 N.
Very different demands are placed in the textile industry on nonwoven
materials used in the
manufacture of winter clothing. Apart from the stress resistance, which is
expressed in the tear
resistance of the material used, good workability, drapability and softness,
as well as, depending on
the intended use, the smallest possible material thickness with at the same
time a good heat
insulation capacity are of interest. So far, materials with a good heat
insulation capacity are woven
from different fibre mixtures or felts of animal hair are produced. While the
woven materials have a
tendency to unravel or fray and therefore must be hemmed, the felt materials
have a very high
surface weight. With woven materials, one must also always consider the
orientation of the fabric
with respect to its stress resistance.
It is an object of the invention to provide a low cost thermofleece which has
a breaking
strength or tear resistance > 150 N as well as a process for its manufacture.
This object is achieved in accordance with the invention by a thermofleece
which consists
of a microfilament nonwoven with basis weights or surface weights of 60-300
g/m2 as well as a tear
resistance >150 N, whereby the microfilament nonwoven consists of meltspun,
stretched
multicomponent endless filaments which are immediately laid down in a fleece
and have a titre of
1.5-5 dtex, and whereby the multicomponent endless filaments, optionally after
a preconsolidation,
are split at least to 80% into micro endless filaments with a titre of 0.1-1.0
dtex and consolidated.
With the thermofleece in accordance with the invention, a hemming is no longer
necessary because
of the endless filaments and no unraveling occurs.
The thermofleece is preferably one in which the nonwoven consists of meltspun,
aerodynamically stretched multicomponent endless filaments laid down
immediately into a fleece
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CA 02395462 2002-06-21
and having a titre of 1.5-3 dtex and the multicomponent endless filaments,
optionally after a
preconsolidation, are split at least to 80% into micro endless filaments with
a titre of 0.1-0.8 dtex
and consolidated. The thermofleece has an isotropic filament distribution in
the fleece. Thus, a
consideration of the machine direction during the cutting of the thermofleece
is not required.
The thermofleece is preferably one wherein the multicomponent endless filament
is a
bicomponent endless filament made of two incompatible polymers, especially a
polyester and a
polyamide. Such a bicomponent endless filament has a good splittability into
micro endless
filaments and causes an advantageous ratio of strength to surface weight. At
the same time, the
thermofleece in accordance with the invention is wrinkle resistant, easily
washable and fast drying,
which means easy care, because of the polymers used and their filament
structure.
The thermofleece is preferably one in which the multicomponent endless
filaments have a
cross-section with an orange-type multisegment structure also called "pie"
structure whereby the
segments altematingly contain respectively one of the two incompatible
polymers. Apart from this
orange-type multisegment structure of the multicomponent endless filaments, a
side by side (s/s)
segment placement of the incompatible polymers in the multicomponent endless
filament is also
possible, which preferably is used for the production of crimped filaments.
Such segment
placements of the incompatible polymers in the multicomponent endless filament
have proven to be
very easily splittable. The thermofleece has a very good heat insulation
capacity in relation to its
thickness and/or the weight, so that soft and warm winter clothing can be
produced especially with
subsequent treatment steps such as roughing or sanding.
The thermofleece is preferably one in which one of the incompatible polymers
forming the
multicomponent endless filaments includes an additive, such as color pigments,
permanently active
anti-statics, fungicides, bactericides, acaricides and/or additives which
influence the hydrophilic or
hydrophobic properties in amounts up to 10% per weight. The thermofleece
consisting of spun
colored fibres has a very good wash fastness. Furthermore, static charging can
be reduced or
prevented by the additives and the humidity transferred properties can be
improved. The
thermofleece has very good care properties with respect to its washability and
a short drying time.
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CA 02395462 2002-06-21
The process in accordance with the invention for the manufacture of a
thermofleece material
consists in that the multicomponent endless filaments are spun from the melt,
stretched and
immediately laid into a fleece, a preconsolidation is carried out and the
fleece material is
consolidated by high pressure fluid jets and simultaneously split into micro
endless filaments with a
titre of 0.1-1.0 dtex, preferably into micro endless filaments with a titre of
0.1-0.8 dtex. The
thermofleece so obtained is very even with respect to its thickness, has an
isotropic thread
distribution, has no propensity to delaminate and is characterized by high
module values.
The process for the manufacture of the thermofleece is preferably carried out
in such a
manner that the consolidation and splitting of the micro component endless
filaments is carried out
such that the preconsolidated fleece material is impacted at least one on each
side by high pressure
water jets. The thermofleece thereby has a good surface and a degree of
splitting of the micro
component endless filaments >80%.
A process is especially preferred in which the multicomponent endless
filaments are spin
colored. The binding of the pigments into the polymer filaments leads to
exceptional wash fastness.
The thermofleece manufactured according to the invention is especially used
for the
manufacture of inner pockets, inner lining materials or upper materials. It is
further suited for use as
wadding or padding.
Example 1
A filament mat with a surface weight of 120 g/mZ is produced from a polyester-
polyamide
(PES-PA) bicomponent endless filament and on both sides subjected to a water
jet needling at
pressures up to 230 bar. The bicomponent endless filaments after the water jet
needling, which leads
to a simultaneous splitting of the starting filaments, have a titre of 1.0
dtex. The micro endless
filament nonwoven obtained has a water vapor pass-through index iNT of 0.56.
The heat insulation
capacity expressed by the heat transfer resistance Rt is 42.5 x 10-3 mZK/W and
the water vapor pass-
through resistance Re, is 4.58 m2Pa/W.
CLAIMS
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