CA2533688A1 - Stitch-bonded and gathered composites and methods for making same - Google Patents

Stitch-bonded and gathered composites and methods for making same Download PDF

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Publication number
CA2533688A1
CA2533688A1 CA002533688A CA2533688A CA2533688A1 CA 2533688 A1 CA2533688 A1 CA 2533688A1 CA 002533688 A CA002533688 A CA 002533688A CA 2533688 A CA2533688 A CA 2533688A CA 2533688 A1 CA2533688 A1 CA 2533688A1
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CA
Canada
Prior art keywords
composite
layer
shrinkable
stitch
heat shrinkable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002533688A
Other languages
French (fr)
Other versions
CA2533688C (en
Inventor
Dimitri P. Zafiroglu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DZS LLC
Original Assignee
Dzs, Llc
Dimitri P. Zafiroglu
Swz, Llc
Sdz, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dzs, Llc, Dimitri P. Zafiroglu, Swz, Llc, Sdz, Llc filed Critical Dzs, Llc
Publication of CA2533688A1 publication Critical patent/CA2533688A1/en
Application granted granted Critical
Publication of CA2533688C publication Critical patent/CA2533688C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/027—Thermal properties
    • B32B7/028—Heat-shrinkability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/02—Pile fabrics or articles having similar surface features
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/008—Sewing, stitching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B32B2307/736—Shrinkable
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets
    • D10B2503/041—Carpet backings
    • 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
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • 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
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • 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.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3976—Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Abstract

Disclosed herein is a composite (10) comprising at least one heat shrinkable adhesive layer (12) stitch-bonded with yams (50), which shrink less than the adhesive layer (12) or do not shrink, when the adhesive layer (12) is exposed to heat. The stitch-bonded yams (50) form loops (28) upstanding from the shrunk adhesive layer and the loops (28) create a textured surface on the composite, and the composite (10) is substantially inelastic after the adhesive layer (12) is shrunk. The composite may further comprise at least one fibrous layer (30) stitch-bonded to the shrinkable adhesive layer, and the fibrous layer (30) is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Claims (74)

What is claimed is:
1. A composite comprising at least one heat shrinkable layer stitch-bonded with a network of yarns wherein the shrinking temperature of the shrinkable layer is lower than the melting temperature of the stitch-bonded yarns, and wherein shrinkable layer shrinks and causes the stitch-bonded yarns to form loops emanating from the shrunk layer, and wherein the shrunk layer is substantially inelastic.
2. The composite of claim 1, wherein the loops have a frequency of at least 10 per inch in at least one direction and a height of less than about 2.0 mm.
3. The composite of claim 1, wherein the shrunk composite is dimensionally stable.
4. The composite of claim 1, wherein the stretchability of the shrunken composite is less than about 20% strain under a 5 lb/inch pull on a 1 inch wide by 8 inch long strip of the composite.
5. The composite of claim 1, wherein the heat shrinkable layer comprises a non-woven fabric, a woven fabric or a knit fabric.
6. The composite of claim 1, wherein the heat shrinkable layer comprises a plastic film.
7. The composite of claim 1, wherein the heat shrinkable layer is shrinkable by about 10% to about 50% in at least one direction.
8. The composite of claim 7, wherein the heat shrinkable layer is shrinkable in two directions.
9. The composite of claim 1, wherein the heat shrinkable layer is shrinkable by at least about 20% in at least one direction.
10. The composite of claim 9, wherein the heat shrinkable layer is shrinkable in two directions.
11. The composite of claim 1, wherein the yarns are substantially non-shrinkable.
12. The composite of claim 1, wherein the yarns comprise a flat filament yarn.
13. The composite of claim 1, wherein the yarns comprise a staple-based yarn.
14. The composite of claim 1, wherein the yarns comprise a bulked twisted filament yarn.
15. The composite of claim 1, wherein the yarns comprise a composite staple/continuous filament yarn.
16. The composite of claim 1, wherein the yarns comprise textured polymeric yarns
17. The composite of claim 1, wherein the yarns comprise composite flat and textured yarns.
18. The composite of claim 1, wherein the yarns are stitched to the heat shrinkable layer in accordance with two or more distinct stitching patterns.
19. The composite of claim 1, further comprising at least one fibrous layer stitch-bonded to the heat shrinkable layer.
20. The composite of claim 19, wherein the fibrous layer is less shrinkable than the heat shrinkable layer.
21. The composite of claim 20, wherein the fibrous layer is substantially non-shrinkable.
22. The composite of claim 20, wherein the fibrous layer forms second loops when the heat shrinkable layer shrinks.
23. The composite of claim 20, wherein the fibrous layer is bonded to the heat shrinkable layer at locations proximate the stitching points.
24. The composite of claim 19, wherein the fibrous layer is positioned on the technical front of the heat shrinkable layer.
25. The composite of claim 19, wherein the fibrous layer is positioned on the technical back of the heat shrinkable layer.
26. The composite of claim 19, wherein the fibrous layer comprises from about 10% up to about 50% low melt binder, the low melt binder bonding surface fibers within the fibrous layer.
27. The composite of claim 19, wherein the fibrous layer comprises a non-woven layer, a woven layer, a knit layer or a stitch-bonded layer.
2~. The composite of claim 19, wherein the non-woven layer is a spunlaced nonwoven.
29. The composite of claim 1, wherein the composite is stitch-bonded with a gauge from about 3 per inch up to about 22 per inch and a CPI from about 6 per inch up to about 24 per inch.
30. The composite of claim 1, wherein the composite is stitch-bonded with a gauge from about 9 per inch up to about 22 per inch and a CPI from about 12 per inch up to about 24 per inch.
31. The composite of claim1, wherein the heat shrinkable layer is an adhesive layer.
32. The composite of claim 31, wherein the adhesive layer comprises a thermoplastic adhesive.
33. The composite of claim 32, wherein the thermoplastic adhesive comprises a polyolefin.
34. The composite of claim1 further comprising an adhesive layer.
35. The composite of claim 34, wherein the adhesive layer is stitch-bonded to the heat shrinkable layer.
36. The composite of claim 34, wherein the adhesive layer is substantially non-shrinkable.
37. The composite of claim 34, wherein the adhesive layer is shrinkable.
38. The composite of claim 31, wherein the adhesive layer shrinks to a flat layer.
39. The composite of claim 31, wherein the adhesive layer is activated to encase the vertical portions of the stitch-bonded yarns passing through the adhesive layer.
40. The composite of claim 1, wherein the composite is laminated to a backing layer.
41. The composite of claim 1, wherein the composite is embossed to a backing layer.
42. A method of making a composite comprising:
providing a heat shrinkable layer;
stitch-bonding the heat shrinkable layer with yarns that are less shrinkable than the heat shrinkable layer;
exposing the stitch-bonded heat shrinkable layer to heat to shrink said layer;
and said shrinkage causing loops emanating from the shrunk layer to form from the stitch-bonding yarns.
43. The method of claim 42, wherein the step of providing the heat shrinkable layer comprises the step of selecting said layer to be shrinkable by about 10% to about 50% in at least one direction.
44. The method of claim 43, wherein the heat shrinkable layer is shrinkable in two directions.
45. The method of claim 42, wherein the step of providing the heat shrinkable layer comprises the step of selecting said layer to be shrinkable by at least about 20% in at least one direction.
46. The method of claim 45, wherein the heat shrinkable layer is shrinkable in two directions.
47. The method of claim 42, wherein the step of stitch-bonding the heat shrinkable layer comprises stitching in two or more distinct stitching patterns.
48. The method of claim 42, wherein the composite is laminated to a backing layer.
49. The method of claim 42, wherein the composite is embossed to a backing layer.
50. The method of claim 42, further comprising the steps of selecting a fibrous layer and stitch-bonding the fibrous layer with the heat shrinkable layer.
51. The method of claim 50, wherein the fibrous layer comprises a spunlaced nonwoven.
52. The method of claim 50, wherein the step of selecting the fibrous layer includes selecting a fibrous layer that is substantially non-shrinkable.
53. The method of claim 50, wherein the step of selecting the fibrous layer includes selecting a fibrous layer that is less shrinkable than the heat shrinkable layer.
54. The method of claim 50, further comprising the step of forming second loops created from the fibrous layer.
55. The method of claim 42, wherein the heat shrinkable layer is an adhesive layer.
56. The method of claim 42 further comprising the steps of providing an adhesive layer and bonding the adhesive layer to the heat shrinkable layer.
57. The method of claim 56, wherein the adhesive layer is shrinkable.
58. The method of claim 56, wherein the adhesive layer is substantially non-shrinkable.
59. The method of claim 55, wherein the step of exposing the stitch-bonded adhesive layer includes the step of bonding the stitch-bonding yarns to the adhesive layer.
60. The method of claim 56, wherein the step of exposing the stitch-bonded adhesive layer includes the step of bonding the stitch-bonding yarns to the adhesive layer.
61. A composite comprising at least one heat shrinkable layer stitch-bonded with yarns that shrink less than the heat shrinkable layer when the composite is exposed to heat, wherein the stitch-bonded yarns form loops upstanding from the shrunk layer and the loops create a textured surface on the composite and wherein the composite is substantially inelastic after the heat shrinkable layer is shrunk.
62. The composite of claim 61, wherein the heat shrinkable layer is an adhesive layer.
63. The composite of claim 61 further comprises an adhesive layer.
64. The composite of claim 63, wherein the adhesive layer is substantially non-shrinkable.
65. The composite of claim 63, wherein the adhesive layer is shrinkable.
66. The composite of claim 63, wherein the adhesive layer is stitch-bonded to the heat shrinkable layer.
67. The composite of claim 61, wherein the stitch-bonded yarns are substantially non-shrinkable.
68. The composite of claim 61 further comprising at least one fibrous layer stitch-bonded to the shrinkable adhesive layer.
69. The composite of claim 61, wherein the fibrous layer is less shrinkable than the adhesive layer.
70. The composite of claim 61, wherein the fibrous layer is substantially non-shrinkable.
71. The composite of claim 70, wherein the fibrous layer forms second loops when the adhesive layer shrinks.
72. The composite of claim 61, wherein the stretchability of the composite is less than about 20% strain under a 5 lb/inch pull on a 1 inch wide by 8 inch long strip of the composite.
73. The composite of claim 72, wherein the stretchability is less than about 10%.
74. The composite of claim 63, wherein the adhesive layer is applied to the heat shrinkable layer.
CA2533688A 2003-07-01 2004-06-28 Stitch-bonded and gathered composites and methods for making same Expired - Fee Related CA2533688C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/611,287 US6936327B2 (en) 2003-07-01 2003-07-01 Stitch-bonded and gathered composites
US10/611,287 2003-07-01
PCT/US2004/023771 WO2005002839A2 (en) 2003-07-01 2004-06-28 Stitch-bonded and gathered composites and methods for making same

Publications (2)

Publication Number Publication Date
CA2533688A1 true CA2533688A1 (en) 2005-01-13
CA2533688C CA2533688C (en) 2010-09-21

Family

ID=33552350

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2533688A Expired - Fee Related CA2533688C (en) 2003-07-01 2004-06-28 Stitch-bonded and gathered composites and methods for making same

Country Status (5)

Country Link
US (2) US6936327B2 (en)
EP (1) EP1644188B1 (en)
CN (2) CN101586313B (en)
CA (1) CA2533688C (en)
WO (1) WO2005002839A2 (en)

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Also Published As

Publication number Publication date
US20050227038A1 (en) 2005-10-13
CN1812884A (en) 2006-08-02
CN100522606C (en) 2009-08-05
WO2005002839A2 (en) 2005-01-13
EP1644188A4 (en) 2007-08-29
WO2005002839A3 (en) 2005-09-15
US7255761B2 (en) 2007-08-14
CA2533688C (en) 2010-09-21
US6936327B2 (en) 2005-08-30
US20050003140A1 (en) 2005-01-06
CN101586313A (en) 2009-11-25
CN101586313B (en) 2011-05-18
EP1644188B1 (en) 2014-02-26
EP1644188A2 (en) 2006-04-12

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