CA1076015A - Method for forming a vinyl coated needle punched, non-woven web and product thereof - Google Patents
Method for forming a vinyl coated needle punched, non-woven web and product thereofInfo
- Publication number
- CA1076015A CA1076015A CA238,861A CA238861A CA1076015A CA 1076015 A CA1076015 A CA 1076015A CA 238861 A CA238861 A CA 238861A CA 1076015 A CA1076015 A CA 1076015A
- Authority
- CA
- Canada
- Prior art keywords
- plastisol
- vinyl
- release paper
- woven
- substrate
- 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.)
- Expired
Links
Landscapes
- Laminated Bodies (AREA)
Abstract
METHOD FOR FORMING A VINYL COATED
NEEDLE PUNCHED, NON-WOVEN WEB AND
PRODUCT THEREOF
Abstract of the Disclosure Vinyl coated needle punched, non-woven webs, either with or without a foam interlayer, suitable for use in various coated fabric products and having a uniform surface quality are formed by casting a fluid vinyl plastisol onto release paper, laminating a non-woven substrate to the plastisol while it is in either the fluid state or, while it is in either a partially gelled or fused state with additional vinyl plastisol as an ad-hesive, fusing the unfused plastisol layer or layers, and separ-ating the release paper.
NEEDLE PUNCHED, NON-WOVEN WEB AND
PRODUCT THEREOF
Abstract of the Disclosure Vinyl coated needle punched, non-woven webs, either with or without a foam interlayer, suitable for use in various coated fabric products and having a uniform surface quality are formed by casting a fluid vinyl plastisol onto release paper, laminating a non-woven substrate to the plastisol while it is in either the fluid state or, while it is in either a partially gelled or fused state with additional vinyl plastisol as an ad-hesive, fusing the unfused plastisol layer or layers, and separ-ating the release paper.
Description
Technical Description of the Invention Vinyl coated, non-woven substrates find use as materials for upholstery, luggage, case coverings, pocketbooks, garments, footwear, automotive trim, etc., but, when the vinyl coating or film is rather thin, i.e., having a thic~ness of about 4 to about 30 mils, they often possess the undesirable charac_sristic that the substrate surface irregularities may be transmitted to the surface of the vinyl film giving it a waffled appearance. Of the many prior attempts made to solve this problem none were fully successful although degrees of improvement were found in some cases. The basic prior art process for forming such a product in-volved the lamination of a solid vinyl film with a suitable non-woven substrate. Such modifications in the basic process as vary-ing the number or size of the fibers in the non-woven substrate, precalendering of the substrate, adjusting the tension on either the non-woven substrate or film, or both, during the lamination step, calendering the film to a certain defined gauge, and utiliz-ing a non-stretch woven support fabric as a carrier for either the film or the substrate have not acceptably eliminated the waffling of the laminated product resulting from the lamination step.
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C-42gl The process of this invention forms a vinyl coated, non, woven substrate having a uniform or unwaffled surface by first casting an unfused vinyl plastisol composition onto release paper, laminating a non-woven substrate either into a portion of the plastisol while it is in the fluid state or to a gelled plastisol or fused film with the aid of a vinyl plastisol adhesive there-between, heating to fuse the respective unfused plastisol or adhesive portions, cooling the product formed thereby, and then separating the release paper and the fused plastisol-substrate ll laminate.
The vinyl plastisol composition which is used in the , initial step of the above described process is well-known to 3), persons of skill in the art. It preferably comprises about 45%
to 55~ by weight of a homopolymer of polyvinyl chloride and has , a plasticizer content of about 25% to 40% by weight. If desired,' copolymers of vinyl chloride with such monomers as vinyl acetate,i vinylidene chloride, the olefins, the alkyl acrylates and the other well known monomers which copolymerize well with vinyl chloride ~ monomer can also be used. If the plastisol composition is either;
~ partially gelled or fused, it is preferable to use an effective ;- -; amount, e.g., about 1 to about 3 mils, of a vinyl plastisol ad-hesive during lamination to bond the substrate to the vinyl film , during the final fusing operation. The terminology "vinyl plastir sol" is intended to cover both homo- as well as copolymers of vinyl chloride in such plastisol form. Examples of suitable plasticizers which are compatible with polyvinyl chloride may be selected from`
the appropriate phosphate esters, phthalic acid derivatives, epoxy derivatives, adipic acid derivatives, azelaic acid derivatives and sebacic acid derivatives listed in Modern Plastics Encyclopedia, Vol. 50, No. lOA (1973) ` C-4291 10760~5 ; The total amount of plastisol which is applied to the release paper should be from about 0.004 in. to 0.040 in., depend-ing upon the particular end use of the product. For upholstery about 0.020 in. is preferably used. The plastisol is applied to the release paper at a temperature of about 15C. to about 30C.
When an embossed final product is desired, the release paper should be embossed before the plastisol is applied. Generally, embossing is desired in most applications since it presents a more pleasant, ; ` visual impression. All of the plastisol can either be applied to l¦ the releas~ paper in a single step or it can'be applied in two ~! steps with partial or complete fu ing of the first layer by heat-1, ing from about 105C. to about 220C for about 10 to 30 seconds,followed by gravure, reverse roll, knife or wire wound rod appli-cation of about 0.001 in. to about 0.003 in. thickness of a vinyl lS ' plastisol adhesive. The term "plastisol composition" as used ' herein is meant to encompass compositions used in these possible embodiments which in the latter case may be either the same or different for each of the two portions applied.
~ After all of the plastisol has been applied by either-' one or two steps, a suitable needle punched non-woven substrate ' is laminated approximately one to three mils deep into the still !
fluid plastisol. If the plastisol is all applied in one stçp, . , lamination is preferably accomplished by passing the plastisol covered release paper and sLbstrate through a fixed clearance ~. i nip which is dimensioned to cause the desired lamination, but which does not cause the fluid plastisol to penetrate the sub-strate to an objectionable degree. In the two step applicatinn of the plastisol wherein most of the plastisol is applied and either gelled or fused, then a 0.001 in. to 0.003 in. thick layer of adhesive is applied as the second step, the non-woven web can ~, C-4291 , ` be laminated into the adhesive by passing the plastisol coated .
paper and the non-woven substrate between a set of squeeæ rolls.
The non-woven substrate preferably has a thickness of about 0.20 to about 0.150 inches.
In cases of composite fiber-foam substrates the types of foamswhich can be used comprise polyurethane foams, cured natural and synthetic rubber foams and other types which will not be adversely affected by the temperatures and pressures ,I required to produce the completed laminate. The types of fibers ' which may be used in combination with such foams are preferably ! polyamide, polyurethane, fiber glass, polyester, polyacrylonitrile, 'l cellulosics, including cotton and rayons made by the xanthate :j ,- process, and others which will not be affected by the temperatures , and pressures required to produce the completed laminate. Blends~
of these fibers may also be used. As used herein the te~m "non-woven fiber substrate" is meant to encompass substrates which consist essentially of the needle punched non-woven fibers as well as substrates which comprise a preformed foam into which staple fibers have been needle punched.
After the fluid plastisol-substrate laminate has been formed the plastisol layer is fused into a solid vinyl film by ~' heating the laminate to a temperature of about 160C. to 220C.
for about 3/4 to about 1-1/2 min. utilizing conventional procedures ~ for fusing such plastisol compositions. The release paper and fused plastisol-substrate laminate are cooled and are then separated to yield a vinyl coated-needle punched non-woven web ~ .
composite laminate having an unwaffled, uniform surface quality in the vinyl film.
The invention is further illustrated by the following Examples:
10760~5 , EXAMPLE I
The following plastisol composition was prepared using conventional plastisol mixing procedures:
COMPONENTAMOUNT (% BY WEIGHT) Polyvinyl chloride 5 , dispersion resin 50.31 I Calcium Carbonate (Atomité) 10.07-¦ Vinyl stabilizer 1.45 ll Epoxidized Soybean Oil2.52 10 ¦¦ Di-2 ethylhexyl phthalate24.65 ~ Pigment in plasticizer - ~! composition* 11.00 f~* Comprises 5.22% carbon black, ,28.77~ antimony oxide, i - 62.06~ di-2 ethylhexyl phthalate,l.05% vinyl chloride ' dispersion resin and 2.90% epoxy tallate.
The above plastisol composition WAS cast onto release ~paper, mfg. by S. D. Warren, having a slightly embossed grain so that the thickness of the coating was about 15 mils. The coating was gelled on a steel drum machine at a temperature of about 140C.
The gelled plastisol - release paper article was then conveyed to a reverse roll coater machine where an additional 6 mils of plasti-¦
sol was applied. A substrate comprising polyester fibers needle punched into a polyurethane foam (foam thickness 63 mils; approx.
total weight of substrate was 3.5 oz/yd2; manufactured by Foss Manufacturing Co.) was then laminated by means of a fixed clearanc~
nip to this last fluid portion. The laminate was fused in an oven, at a temperature of 160C. to 200C. The product that resulted therefrom had no waffling.
. ~
., , EXAMPLE II
A plastisol composition according to Example I was reverse roller coated on Madrid embossed release paper to an approximate weight of 18 oz/yd2. The plastisol was gelled at about 105-145C. using radiant electric heaters. About 0.002 in.
of a vinyl adhesive having the following composition was then ~ applied to the gelled plastisol layer:
I COMPONENTAMOUNT (~ BY WEIG~T) Vinyl dispersion resin 53.72 ll Di-2 ethylhexyl phthalate43.23 10 ~1 Expoxidized soybean oil3.05 A needle punched fiber/foam substrate as described in Example I was applied to this adhesive via a pressure nip. The ' laminate formed thereby was heated to about 180C. by passing through an oven to compIete fusion of the plastisol. The product was then cooled, and the release paper was stripped with the resulting finished product wound on a roll for further disposition.
The product showed no signs of waffling, and there was good adhesion between the non-woven substrate and vinyl film.
.
: ~:: : .. :.
' : ' ' ~' ~;
,: ::. ~ .
C-42gl The process of this invention forms a vinyl coated, non, woven substrate having a uniform or unwaffled surface by first casting an unfused vinyl plastisol composition onto release paper, laminating a non-woven substrate either into a portion of the plastisol while it is in the fluid state or to a gelled plastisol or fused film with the aid of a vinyl plastisol adhesive there-between, heating to fuse the respective unfused plastisol or adhesive portions, cooling the product formed thereby, and then separating the release paper and the fused plastisol-substrate ll laminate.
The vinyl plastisol composition which is used in the , initial step of the above described process is well-known to 3), persons of skill in the art. It preferably comprises about 45%
to 55~ by weight of a homopolymer of polyvinyl chloride and has , a plasticizer content of about 25% to 40% by weight. If desired,' copolymers of vinyl chloride with such monomers as vinyl acetate,i vinylidene chloride, the olefins, the alkyl acrylates and the other well known monomers which copolymerize well with vinyl chloride ~ monomer can also be used. If the plastisol composition is either;
~ partially gelled or fused, it is preferable to use an effective ;- -; amount, e.g., about 1 to about 3 mils, of a vinyl plastisol ad-hesive during lamination to bond the substrate to the vinyl film , during the final fusing operation. The terminology "vinyl plastir sol" is intended to cover both homo- as well as copolymers of vinyl chloride in such plastisol form. Examples of suitable plasticizers which are compatible with polyvinyl chloride may be selected from`
the appropriate phosphate esters, phthalic acid derivatives, epoxy derivatives, adipic acid derivatives, azelaic acid derivatives and sebacic acid derivatives listed in Modern Plastics Encyclopedia, Vol. 50, No. lOA (1973) ` C-4291 10760~5 ; The total amount of plastisol which is applied to the release paper should be from about 0.004 in. to 0.040 in., depend-ing upon the particular end use of the product. For upholstery about 0.020 in. is preferably used. The plastisol is applied to the release paper at a temperature of about 15C. to about 30C.
When an embossed final product is desired, the release paper should be embossed before the plastisol is applied. Generally, embossing is desired in most applications since it presents a more pleasant, ; ` visual impression. All of the plastisol can either be applied to l¦ the releas~ paper in a single step or it can'be applied in two ~! steps with partial or complete fu ing of the first layer by heat-1, ing from about 105C. to about 220C for about 10 to 30 seconds,followed by gravure, reverse roll, knife or wire wound rod appli-cation of about 0.001 in. to about 0.003 in. thickness of a vinyl lS ' plastisol adhesive. The term "plastisol composition" as used ' herein is meant to encompass compositions used in these possible embodiments which in the latter case may be either the same or different for each of the two portions applied.
~ After all of the plastisol has been applied by either-' one or two steps, a suitable needle punched non-woven substrate ' is laminated approximately one to three mils deep into the still !
fluid plastisol. If the plastisol is all applied in one stçp, . , lamination is preferably accomplished by passing the plastisol covered release paper and sLbstrate through a fixed clearance ~. i nip which is dimensioned to cause the desired lamination, but which does not cause the fluid plastisol to penetrate the sub-strate to an objectionable degree. In the two step applicatinn of the plastisol wherein most of the plastisol is applied and either gelled or fused, then a 0.001 in. to 0.003 in. thick layer of adhesive is applied as the second step, the non-woven web can ~, C-4291 , ` be laminated into the adhesive by passing the plastisol coated .
paper and the non-woven substrate between a set of squeeæ rolls.
The non-woven substrate preferably has a thickness of about 0.20 to about 0.150 inches.
In cases of composite fiber-foam substrates the types of foamswhich can be used comprise polyurethane foams, cured natural and synthetic rubber foams and other types which will not be adversely affected by the temperatures and pressures ,I required to produce the completed laminate. The types of fibers ' which may be used in combination with such foams are preferably ! polyamide, polyurethane, fiber glass, polyester, polyacrylonitrile, 'l cellulosics, including cotton and rayons made by the xanthate :j ,- process, and others which will not be affected by the temperatures , and pressures required to produce the completed laminate. Blends~
of these fibers may also be used. As used herein the te~m "non-woven fiber substrate" is meant to encompass substrates which consist essentially of the needle punched non-woven fibers as well as substrates which comprise a preformed foam into which staple fibers have been needle punched.
After the fluid plastisol-substrate laminate has been formed the plastisol layer is fused into a solid vinyl film by ~' heating the laminate to a temperature of about 160C. to 220C.
for about 3/4 to about 1-1/2 min. utilizing conventional procedures ~ for fusing such plastisol compositions. The release paper and fused plastisol-substrate laminate are cooled and are then separated to yield a vinyl coated-needle punched non-woven web ~ .
composite laminate having an unwaffled, uniform surface quality in the vinyl film.
The invention is further illustrated by the following Examples:
10760~5 , EXAMPLE I
The following plastisol composition was prepared using conventional plastisol mixing procedures:
COMPONENTAMOUNT (% BY WEIGHT) Polyvinyl chloride 5 , dispersion resin 50.31 I Calcium Carbonate (Atomité) 10.07-¦ Vinyl stabilizer 1.45 ll Epoxidized Soybean Oil2.52 10 ¦¦ Di-2 ethylhexyl phthalate24.65 ~ Pigment in plasticizer - ~! composition* 11.00 f~* Comprises 5.22% carbon black, ,28.77~ antimony oxide, i - 62.06~ di-2 ethylhexyl phthalate,l.05% vinyl chloride ' dispersion resin and 2.90% epoxy tallate.
The above plastisol composition WAS cast onto release ~paper, mfg. by S. D. Warren, having a slightly embossed grain so that the thickness of the coating was about 15 mils. The coating was gelled on a steel drum machine at a temperature of about 140C.
The gelled plastisol - release paper article was then conveyed to a reverse roll coater machine where an additional 6 mils of plasti-¦
sol was applied. A substrate comprising polyester fibers needle punched into a polyurethane foam (foam thickness 63 mils; approx.
total weight of substrate was 3.5 oz/yd2; manufactured by Foss Manufacturing Co.) was then laminated by means of a fixed clearanc~
nip to this last fluid portion. The laminate was fused in an oven, at a temperature of 160C. to 200C. The product that resulted therefrom had no waffling.
. ~
., , EXAMPLE II
A plastisol composition according to Example I was reverse roller coated on Madrid embossed release paper to an approximate weight of 18 oz/yd2. The plastisol was gelled at about 105-145C. using radiant electric heaters. About 0.002 in.
of a vinyl adhesive having the following composition was then ~ applied to the gelled plastisol layer:
I COMPONENTAMOUNT (~ BY WEIG~T) Vinyl dispersion resin 53.72 ll Di-2 ethylhexyl phthalate43.23 10 ~1 Expoxidized soybean oil3.05 A needle punched fiber/foam substrate as described in Example I was applied to this adhesive via a pressure nip. The ' laminate formed thereby was heated to about 180C. by passing through an oven to compIete fusion of the plastisol. The product was then cooled, and the release paper was stripped with the resulting finished product wound on a roll for further disposition.
The product showed no signs of waffling, and there was good adhesion between the non-woven substrate and vinyl film.
2 EXAMPLE III
- A plastisol composition according to Example I was reverse roller coated on Madrid embossed release paper to an approximate weight of 18 oz/yd2. A non-woven substrate as des-cribed in Example I was laminated to the wet unfused plastisol by means of a fixed clearance nip having a gap which prevented penetration of the plastisol through the substrate. The laminate was then heated to about 160C. to 220C. for about
- A plastisol composition according to Example I was reverse roller coated on Madrid embossed release paper to an approximate weight of 18 oz/yd2. A non-woven substrate as des-cribed in Example I was laminated to the wet unfused plastisol by means of a fixed clearance nip having a gap which prevented penetration of the plastisol through the substrate. The laminate was then heated to about 160C. to 220C. for about
3/4 min. to 1-1/2 min. utilizing a suitable over. The product was then cooled, the release paper was stripped, and the product - ;
~-4291 107 60~ 5 was wound up on a roll for further disposition. It showed no signs of waffling. The product also showed a desirable plushness ~
and bulkiness not inherent in such products made by other processes.
I
'` ; ' . ' , ~
`
1.
~-4291 107 60~ 5 was wound up on a roll for further disposition. It showed no signs of waffling. The product also showed a desirable plushness ~
and bulkiness not inherent in such products made by other processes.
I
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`
1.
Claims (12)
1. A process for forming a vinyl coated, needle punched non-woven fiber substrate having a uniform surface quality which comprises:
a) casting in a single step a fluid vinyl plastisol composition onto release paper;
b) laminating a non-woven fiber substrate to at least a portion of the plastisol while said portion is in the liquid state;
c) fusing the plastisol; and d) separating the release paper and the fused plastisol-substrate laminate.
a) casting in a single step a fluid vinyl plastisol composition onto release paper;
b) laminating a non-woven fiber substrate to at least a portion of the plastisol while said portion is in the liquid state;
c) fusing the plastisol; and d) separating the release paper and the fused plastisol-substrate laminate.
2. A process as claimed in Claim 1 wherein the vinyl plastisol composition comprises a homopolymer of polyvinyl chloride.
3. A process as claimed in Claim 1 wherein the vinyl plastisol composition comprises a copolymer of vinyl chloride and vinyl acetate.
4. A process as claimed in Claim 1 wherein the release paper is embossed.
5. A process as claimed in Claim 1 wherein plastisol is coated onto said release paper in a thickness of about 0.004 to about 0.040 in.
6. A process as claimed in Claim 1 wherein the plastisol contains about 25% to 40% by weight plasticizer.
7. A process as claimed in Claim 1 wherein the plastisol is applied to the release paper at a temperature of about 15°C. to about 30°C.
8. A process as claimed in Claim 1 wherein the non-woven sub-strate also comprises a foam selected from the group consisting of polyurethane foams and the cured natural and synthetic rubber foams.
9. A process as claimed in Claim 1 wherein the fibers form-ing the non-woven substrate are selected from the group consisting of polyurethane, polyamide, polyvinyl chloride, fiber glass, poly-ester, acrylonitrile, cotton, rayons made by the xanthate process, and blends of such fibers.
10. A process as claimed in Claim 1 wherein the non-woven substrate is laminated to the fluid plastisol by use of a fixed clearance nip.
11. A process as claimed in Claim 1 wherein the fluid plastisol is fused by heating to a temperature of about 160°C.
to about 220°C.
to about 220°C.
12. A process as claimed in Claim 1 wherein the fluid plastisol is fused by heating for about 3/4 to about 1-1/2 min.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US52033274A | 1974-11-04 | 1974-11-04 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1076015A true CA1076015A (en) | 1980-04-22 |
Family
ID=24072145
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA238,861A Expired CA1076015A (en) | 1974-11-04 | 1975-11-03 | Method for forming a vinyl coated needle punched, non-woven web and product thereof |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1076015A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0224262A2 (en) * | 1985-11-27 | 1987-06-03 | E.I. Du Pont De Nemours And Company | Fluoropolymer-coated textile material |
| US5441785A (en) * | 1991-01-02 | 1995-08-15 | Liebe, Jr.; Robert J. | Composite alignment-maintaining plastic lettering material |
-
1975
- 1975-11-03 CA CA238,861A patent/CA1076015A/en not_active Expired
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0224262A2 (en) * | 1985-11-27 | 1987-06-03 | E.I. Du Pont De Nemours And Company | Fluoropolymer-coated textile material |
| US4698110A (en) * | 1985-11-27 | 1987-10-06 | E. I. Du Pont De Nemours And Company | Preparation of fluoropolymer coated material |
| EP0224262A3 (en) * | 1985-11-27 | 1988-07-20 | E.I. Du Pont De Nemours And Company | Fluoropolymer-coated textile material |
| US5441785A (en) * | 1991-01-02 | 1995-08-15 | Liebe, Jr.; Robert J. | Composite alignment-maintaining plastic lettering material |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |