CA1317705C - Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristics - Google Patents
Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristicsInfo
- Publication number
- CA1317705C CA1317705C CA000576856A CA576856A CA1317705C CA 1317705 C CA1317705 C CA 1317705C CA 000576856 A CA000576856 A CA 000576856A CA 576856 A CA576856 A CA 576856A CA 1317705 C CA1317705 C CA 1317705C
- Authority
- CA
- Canada
- Prior art keywords
- yarn
- surfactant
- gauze
- wallcovering
- polymeric
- 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 - Fee Related
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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
-
- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
-
- 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
- B32B2607/00—Walls, panels
- B32B2607/02—Wall papers, wall coverings
-
- 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
-
- 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
- Y10T442/164—Including a preformed film, foil, or sheet
Abstract
WALLCOVERING SUBSTRATE FORMED OF TEXTURED, CONTINUOUS, MULTI-FILAMENT YARNS HAVING
HYDROPHILIC CHARACTERISTICS
Abstract of the Disclosure A textured, continuous, multi-filament polyester yarn has an ethoxylated alkyl aryl alcohol based sur-factant incorporated into the interfilamentary struc-ture thereof either during the texturizing process or after the yarn has been made into a gauze-like fabric substrate. The ethoxylated alkyl aryl alcohol based surfactant is characterized in that it is water disper-sible and water insoluble; has an HLB scale in the range of 7-10; is compatible with conventional wallpaper glues, is of a viscosity in the range of 50-100 SUS depending on the yarn denier; and has a smoke point greater than 350°F. The yarn so treated is formed into a gauze fabric substrate and affixed to the rear surface of a sheet material such as a vinyl wallcovering. When the glue is applied to the sheet material the surfactant treatment alters the normally hydrophobic characteristics exhibited by the textured polyester yarn so that the characteristics actually become hydrophilic. Because of the hydrophilic charac-teristics glue is accepted into and held within the interfilamentary structure of the yarn until the sheet material is affixed to the wall or other surface, thereby bonding the substrate thereto.
HYDROPHILIC CHARACTERISTICS
Abstract of the Disclosure A textured, continuous, multi-filament polyester yarn has an ethoxylated alkyl aryl alcohol based sur-factant incorporated into the interfilamentary struc-ture thereof either during the texturizing process or after the yarn has been made into a gauze-like fabric substrate. The ethoxylated alkyl aryl alcohol based surfactant is characterized in that it is water disper-sible and water insoluble; has an HLB scale in the range of 7-10; is compatible with conventional wallpaper glues, is of a viscosity in the range of 50-100 SUS depending on the yarn denier; and has a smoke point greater than 350°F. The yarn so treated is formed into a gauze fabric substrate and affixed to the rear surface of a sheet material such as a vinyl wallcovering. When the glue is applied to the sheet material the surfactant treatment alters the normally hydrophobic characteristics exhibited by the textured polyester yarn so that the characteristics actually become hydrophilic. Because of the hydrophilic charac-teristics glue is accepted into and held within the interfilamentary structure of the yarn until the sheet material is affixed to the wall or other surface, thereby bonding the substrate thereto.
Description
7 r~
WALLCOVRRING SUBSI'RATE FORME~ OF TEXTU~ED, CONTINUOUS, MULTI-FILAMENT YAR~S HAVING
HYDROPHIT~IC CHA~ACTERISTICS
Background and SummarY of the_Present Invention The present invention is directed to substrates for wallcovering, and more speciically to a gauze substrate formed of a synthetic continuous, multi-filament polymeric yarn.
Products such as vinyl wallcovering conventionallymust be provided with a gauze substrate mechanically affixed to the rear surface thereof. The gauze substrate is compatible with a wet bonding agent ~water based glue) to hold the glue in place adjacent the rear of the sheet material until the sheet has been applied to a selected surface (a wall in the case of wallpaper). When the glue or resin has had an oppor-tunity to cure, the gauze substrate (and thus the wallcovering) is bonded to the surface. Vinyl sheet materials will not, in and of themselves, either absorb or hold the glue in place during the curing process, because vinyl is a hydrophobic material.
The gauze substrate is generally woven from a spun yarn formed principally of cellulosic fibers such as cotton. As used herein the term "principally" or "primarily" means 50~ or greater. There are several objections to cotton, but before the present invention no satisfactory solutions to the problems or objections had been developed. The problems or objections are first that spun cellulosic materials are relatively very expensive as compared with a gauze formed of tex-tured, continuous, multi-filament polymeric yarns such as nylon and polyester. The steps involved in forming a spun yarn are several and increase the cost thereof.
Further, it is difficult to weave high cellulosic con-tent yarns on modern, economical high speed, fluid jet ~,~
~3~ 77~
looms (water or air). In the case of water jet loorns the yarn tends to swell in the presence of the water and is therefore difficult to weave. Spun yarns also tend to include more defects than textured yarns, also making the processing more difficult.
Some examples of polyester or other polymeric fibers formed into a non-woven mat or web and used as a backing or base or vinyl wallcoverings are described in U.S. Patents ~o. ~,560,643 and 4,246,311. However, the polyester or polymeric fibers in these illustra-tions are formed into a non-woven web or batt and impregnated with a latex binder. This is also a rela-tively expensive procedure leading to a different type of wallcovering. ~he gauze substrate envisioned by the present invention merely adapts conventional vinyl wallcoverings by affixing (embedding the substrate) into the rear surface resulting in a relatively thin wallcovering.
Previous attempts to use gauze formed of woven, continuous, multi-filament, polymeric yarns such as polyester or nylon as a wallcovering substrate have failed for two reasons First, the textured, con-tinuous multi-filament polymeric yarns generally tend to shrink. Secondly, polymeric materials such as polyester and nylon are generally hydrophobic and tend to repel moisture. Therefore, such yarns are not com-patible to receive and maintain the resinous glue in position as the glue is curing. ~s a result the wallpaper does not bond to the wall surface.
secause of the tremendous savings potential to be realized from the use of woven polymeric gauze, however, efforts have continued to overcome the problems above, thereby adapting up to 100% polyester and/or nylon yarns for use in such gauze substrates.
First, the advent of texturizing procedures which _ 3 - 13177~
resulted in non-shrink polyester encouraged applicant to address seriously the hydrophobic question. After further investigation, it was found that the addition of certain selected surfactants to textured, continuous, multi-filament polyester yarn changed the hydrophobic characteristics of the yarn into more hydrophilic characteristics. The selected surfactant(s) was water dispersible, but not water soluble, so that the surfactant could work its way into the interfilamentary structure, yet not be washed out during the weaving operation. It should be noted that the hydrophobic filaments themselves were not actually made hydrophilic, rather the na-ture of the textured, continuous, multi-filament yarn was hydrophobic in that it no longer tended to repel moisture, but would trap the moisture within the interfilamentary structure thereof.
It has been determined that the surfactants selected should have the characteristics of being water dispersible, but not water soluble; having a hydrophilic, lipophilic bonding factor (HLB scale) in the range of 7-10; and having a smoke point greater than 350F. A surfactant with such characteristics will satisfactorily treat the yarn as part of the texturizing process and be compatible with the water jet weaving operation. Preferably the viscosity of the surfactant is in the range of 50-100 Saybolt Universal Seconds (SUS).
Accordingly, the present invention seeks to provide an improved wa]lcovering gauze substrate.
Further, the present invention seeks to provide a substrate of the type described which is formed of textured, continuous, multi-filament polyester or nylon yarn.
,, , \ .
13~77~
Further still, the present invention seeks to provide a substrate of the type described formed of yarns of the type described in which the polymeric yarns are so treated as to have a hydrophilic characteristic.
Still further, the present invention seeks to form a polyester or nylon gauze substrate which has hydrophilic characteristics to the extent that it will accept and hold conventional water base wallcovering glue until the glue cures thus bonding the substrate to a wall surface.
Still further, the present invention seeks to provide a textured, continuous, multi-filament polyester or nylon yarn that has hydrophilic characteristics.
Other aspects and a fuller understanding of the invention will become apparent from reading the following detailed description of a preferred embodiment along with the accompanying drawings in which:
Figure 1 is a schematic representation of a continuous, multi-filament, textured yarn;
Figure 2 is a schematic representation of a texturizing process which includes a means for applying a chemical treatment according to the present invention;
Figure 3 is a plan view of a woven gauze substrate formed of the yarn of Figures 1 and 2;
Figure 4 is a schematic representation of a processing apparatus for forming a wallcovering with the gauze of Figure 3 embedded therein;
Figure 5 is a sectional view illustrating a wall-covering having the substrate according to -the present invention embedded therein and applied to a wall surface; and Figure 6 is a flow chart describing the steps of the process of the present invention.
: .
13177~
Detailed ~escription of a Preferred ~mbodiment Turning now to the dra~lings, there is described the present invention which has several aspects. First of all, there is provided an improved textured polymeric yarn having hydrophilic characteristics and the method of forming such a yarn; there is provided an improved substrate which is formed predominantly of texturi~ed polymeric yarns which is compatible with water jet weaving operation and which :is so treated as to form a mechanism for adhering such polymeric wallcoverings to wall surfaces; and there is provided a unique wall-covering which utilizes a predominantly polymeric gauze substrate embedded in the rear surface thereof and having the capability of bonding the wallcovering to a wall surface. In general, the common concept which links the foregoing aspects together is the incorporation of a surfactant having certain selected characteristics into a textured, continuous, multi-filament polymeric yarn to provide the polymeric yarn with hydrophilic characteristics, so that when the yarn is formed into a fabric to be utilized as a substrate, the substrate has the unique feature of bonding the vinyl sheet material to a selected surface utilizing conventional water base glues, which vinyl sheet material is otherwise not receptive to said glues.
The first step in accomplishing the invention is best shown in Figures 1 and ~, wherein the textured, continuous, multi-filament, polymeric yarn 10 of Figure 1 has incorporated the aforesaid surfactant thereinto.
The yarn may be formed of several types of polymeric filaments, e.g. polyester and nylon; however, for pur-poses of describing the present invention, polyester has been selected, applied, and tested. Thus the tex-tured yarn 10 of Figure 1 is formed of continuous polyester filaments. It is contemplated that the tech~
13~77~
nique of the present invention would also be ~pplicable to blended yarns, formed predominantly o~ spun poly-meric staple if desired, however, such yarns forms have not been actually tested. It is possible such yarns might have sufficient hydrophilic characteristics because of their surface configuration. If not, however, the teaching of the present invention would be applicable.
In Figure 2, there is illustrated schematically a conventional texturing process in which the multi-filament yarn 10 is passed through a texturing appara-tus 12, which apparatus may utilize any of the conventional texturing processes such as false twist texturing, air jet texturing, stuffer box texturing, edge crimping, gear crimping, and the like. After passing through the texturing apparatus 12, a guide system 1~ directs the yarn 10 over a kiss roll 20, which kiss roll 20 is partially submerged in a trough 16 containing the surfactant 18 to be explained hereinafter. A second guide system 22 directs the chemically treated yarn along to a takeup package 2~.
The chemical itself is a surfactant having certain characteristics or parameters. Since one of the objects of the yarn is to be processed by a water jet loom, the treated yarn will be rewet during the weaving operation. Thus the surfactant must be able to withstand the water from the water jet loom and not be washed out during weaving. Therefore, while the sur-factant should be water dispersible (to enhance disper-sion into the interfilamentary structure of the yarn,it should not be water soluble). Secondly, in order to be receptive to the water based glue the surfactant should have hydrophilic lipophilic bonding charac-teristics such that the HLs factor falls in the range of 7-10. Naturally the surfactant must be compatible with conventional wallcovering glues.
In order to be water dispersible into the inter-filamentary structure of the yarn 10, the sur~actant must have a viscosity in the range of 50-100 Saybolt Universal Seconds (SUS) depending on the yarn.
Finally, since the substrate into which the yarn is woven will be embedded into the vinyl wallcovering during an operation involving heat and pressure, the surfactant must be able to withstand temperatures above a prescribed level. Therefore, the smoke point of the surfactant must be above 350F. One surfactant which has been selected and which has tested satisfactorily has an ethoxylated alkyl ary]. alcohol base.
Specifically the surfactant selected and tested is Lurol 2405 by George A. Goulston, Inc. of Monroe, North Carolina.
The selected surfactant is preferably introduced to the yarn during the texturing process as described and illustrated in Figure 2. Alternatively, the surfactant ! could be applied to the yarn in a separate operation;
while the yarn is on the yarn package; or even after the yarn is woven into the gauze fabric. When intended for use as a substrate for wallcovering, specifications require that a wallcovering be able to e~hibit a 0.35 pound pull strength. Tests have shown that the use of quantities of surfactant in the range of 1.1% by weight of yarn are inadequate to achieve the 0.35 pound pull strength. As a matter of fact, a quantity of 1.1% by weight of surfactant to yarn results in a pull strength of only 0.18 pounds. On the other hand surfactant in amounts of 3% by weight have achieved a pull strength of 0.5 pounds. Therefore, it is believed that surfac-tant in the amount of at least 2.5~ by weight of sur-factant to yarn will be adequate to achieve the 0.35 pound pull strength requirement. In actuality, the weight of the polyester yarn processed was 159 denier ~77Q~
prior to the addition of the additive. In order to achieve the 3~ additive, the speed of the kiss roll 20 was controlled until the yarn denier of the yarn after treatment reached 164.
The application of the surfactant swells the ori-fices (called dye sites) in the textured, multi-filament polyester yarn. The surfactant causes the glue to spread evenly across the surface o~ all filaments to the extent that the glue will bond the polyester fila-ments to the wall surface. Use of the surfactant allows the polyester to beco~e wet and increases the tendency of the surfactant to enter the interfilamen-tary structure of the yarn. Then when the glue or adhesive is applied to the yarn after it is woven into the gauze substrate and embedded in the surface of the wallcovering, the glue adheres to the entire surface of the yarn filaments and actually bonds the substrate to the wall surface. Since the substrate is embedded in the rear surface of the wallcovering, the wallcovering is thus caused to adhere to the wall. Actually the vinyl wallcovering is not, in and of itself glued to the wall, rather the substrate is glued to the wall.
The treated yarn referred to hereinabove is formed into the gauze structure illustrated in Figure 3. The weaving operation is preferably carried out on a fluid jet loom (water or air).
The gauze substrate 30 illustrated in Figure 3 is embedded into the vinyl wallcovering or sheet material 40 as best illustrated in Figure 4. Once the molten vinyl is extruded into sheet material 40 (Figure 4), it is joined to the gauze 30 which is being fed by a feed roll 32. The vinyl sheet material 40 and gauze 30 con-tinue in contiguous arrangement through a pair of calendar rolls 44,46 where the gau7e is caused to be embedded into the underneath surface of the sheet ~3~77~
material 40. The calendar rolls ~l4,~6 are maintained at a temperature of appro~imately 350F. The upper calendar roll 44 may be provided with an embossed pat-tern to decorate the front surface of the vinyl sheeting 40, if desired.
In Figure 5, there is illustrated the completed construction which includes the vinyl wallcovering 40 having the gauze 30 embedded therein joined to a wall surface 50 by a conventional water base glue 52.
Examples of conventional water based wallcovering glues include GT-12 and GT-~60A produced by ~oman Adhesives, Inc. of ~loomfield, New ~ersey. As stated previously, when the glue is applied to the rear surface of the wallcovering ~0 it mechanically affixes to the gauze substrate 30 embedded in the rear surface thereof and bonds the substrate 30 to the surface of wall 50. The moisture in the glue is absorbed into the surfactant clinging to the gauze, and when dry, the glue mechani-cally bonds the gauze to the wall.
In Figure 6, the entire process is summarized.
While the yarn has been described herein as being used in the formation of a gauze substrate for wallcoverings, the yarn itself may have other significant utilization.
To the knowledge of applicant, the yarn of the present ~5 invention is the first incident of a polymeric yarn (hydrophobic characteristics) being modified in the yarn form by the use of a surfactant additive to have hydrophilic characteristics. Secondly, the gauze substrate may have application in other environments than the cited examples of wallcoverings. The gauze substrate oE the present invention permits a hydrophilic gauze to be woven more economically on a water jet loom.
The resulting polyester or polymeric gauze, as a result of the present invention, can then be embedded in a vinyl sheet material which can then be bonded to any desired surface, ~3177~
There has been described in detail hereinabove a preferred embodiment of the present invention. Some modifications have been cited specifically. Other modifications may come to mind. The present invention should be limited only by the following claims.
WALLCOVRRING SUBSI'RATE FORME~ OF TEXTU~ED, CONTINUOUS, MULTI-FILAMENT YAR~S HAVING
HYDROPHIT~IC CHA~ACTERISTICS
Background and SummarY of the_Present Invention The present invention is directed to substrates for wallcovering, and more speciically to a gauze substrate formed of a synthetic continuous, multi-filament polymeric yarn.
Products such as vinyl wallcovering conventionallymust be provided with a gauze substrate mechanically affixed to the rear surface thereof. The gauze substrate is compatible with a wet bonding agent ~water based glue) to hold the glue in place adjacent the rear of the sheet material until the sheet has been applied to a selected surface (a wall in the case of wallpaper). When the glue or resin has had an oppor-tunity to cure, the gauze substrate (and thus the wallcovering) is bonded to the surface. Vinyl sheet materials will not, in and of themselves, either absorb or hold the glue in place during the curing process, because vinyl is a hydrophobic material.
The gauze substrate is generally woven from a spun yarn formed principally of cellulosic fibers such as cotton. As used herein the term "principally" or "primarily" means 50~ or greater. There are several objections to cotton, but before the present invention no satisfactory solutions to the problems or objections had been developed. The problems or objections are first that spun cellulosic materials are relatively very expensive as compared with a gauze formed of tex-tured, continuous, multi-filament polymeric yarns such as nylon and polyester. The steps involved in forming a spun yarn are several and increase the cost thereof.
Further, it is difficult to weave high cellulosic con-tent yarns on modern, economical high speed, fluid jet ~,~
~3~ 77~
looms (water or air). In the case of water jet loorns the yarn tends to swell in the presence of the water and is therefore difficult to weave. Spun yarns also tend to include more defects than textured yarns, also making the processing more difficult.
Some examples of polyester or other polymeric fibers formed into a non-woven mat or web and used as a backing or base or vinyl wallcoverings are described in U.S. Patents ~o. ~,560,643 and 4,246,311. However, the polyester or polymeric fibers in these illustra-tions are formed into a non-woven web or batt and impregnated with a latex binder. This is also a rela-tively expensive procedure leading to a different type of wallcovering. ~he gauze substrate envisioned by the present invention merely adapts conventional vinyl wallcoverings by affixing (embedding the substrate) into the rear surface resulting in a relatively thin wallcovering.
Previous attempts to use gauze formed of woven, continuous, multi-filament, polymeric yarns such as polyester or nylon as a wallcovering substrate have failed for two reasons First, the textured, con-tinuous multi-filament polymeric yarns generally tend to shrink. Secondly, polymeric materials such as polyester and nylon are generally hydrophobic and tend to repel moisture. Therefore, such yarns are not com-patible to receive and maintain the resinous glue in position as the glue is curing. ~s a result the wallpaper does not bond to the wall surface.
secause of the tremendous savings potential to be realized from the use of woven polymeric gauze, however, efforts have continued to overcome the problems above, thereby adapting up to 100% polyester and/or nylon yarns for use in such gauze substrates.
First, the advent of texturizing procedures which _ 3 - 13177~
resulted in non-shrink polyester encouraged applicant to address seriously the hydrophobic question. After further investigation, it was found that the addition of certain selected surfactants to textured, continuous, multi-filament polyester yarn changed the hydrophobic characteristics of the yarn into more hydrophilic characteristics. The selected surfactant(s) was water dispersible, but not water soluble, so that the surfactant could work its way into the interfilamentary structure, yet not be washed out during the weaving operation. It should be noted that the hydrophobic filaments themselves were not actually made hydrophilic, rather the na-ture of the textured, continuous, multi-filament yarn was hydrophobic in that it no longer tended to repel moisture, but would trap the moisture within the interfilamentary structure thereof.
It has been determined that the surfactants selected should have the characteristics of being water dispersible, but not water soluble; having a hydrophilic, lipophilic bonding factor (HLB scale) in the range of 7-10; and having a smoke point greater than 350F. A surfactant with such characteristics will satisfactorily treat the yarn as part of the texturizing process and be compatible with the water jet weaving operation. Preferably the viscosity of the surfactant is in the range of 50-100 Saybolt Universal Seconds (SUS).
Accordingly, the present invention seeks to provide an improved wa]lcovering gauze substrate.
Further, the present invention seeks to provide a substrate of the type described which is formed of textured, continuous, multi-filament polyester or nylon yarn.
,, , \ .
13~77~
Further still, the present invention seeks to provide a substrate of the type described formed of yarns of the type described in which the polymeric yarns are so treated as to have a hydrophilic characteristic.
Still further, the present invention seeks to form a polyester or nylon gauze substrate which has hydrophilic characteristics to the extent that it will accept and hold conventional water base wallcovering glue until the glue cures thus bonding the substrate to a wall surface.
Still further, the present invention seeks to provide a textured, continuous, multi-filament polyester or nylon yarn that has hydrophilic characteristics.
Other aspects and a fuller understanding of the invention will become apparent from reading the following detailed description of a preferred embodiment along with the accompanying drawings in which:
Figure 1 is a schematic representation of a continuous, multi-filament, textured yarn;
Figure 2 is a schematic representation of a texturizing process which includes a means for applying a chemical treatment according to the present invention;
Figure 3 is a plan view of a woven gauze substrate formed of the yarn of Figures 1 and 2;
Figure 4 is a schematic representation of a processing apparatus for forming a wallcovering with the gauze of Figure 3 embedded therein;
Figure 5 is a sectional view illustrating a wall-covering having the substrate according to -the present invention embedded therein and applied to a wall surface; and Figure 6 is a flow chart describing the steps of the process of the present invention.
: .
13177~
Detailed ~escription of a Preferred ~mbodiment Turning now to the dra~lings, there is described the present invention which has several aspects. First of all, there is provided an improved textured polymeric yarn having hydrophilic characteristics and the method of forming such a yarn; there is provided an improved substrate which is formed predominantly of texturi~ed polymeric yarns which is compatible with water jet weaving operation and which :is so treated as to form a mechanism for adhering such polymeric wallcoverings to wall surfaces; and there is provided a unique wall-covering which utilizes a predominantly polymeric gauze substrate embedded in the rear surface thereof and having the capability of bonding the wallcovering to a wall surface. In general, the common concept which links the foregoing aspects together is the incorporation of a surfactant having certain selected characteristics into a textured, continuous, multi-filament polymeric yarn to provide the polymeric yarn with hydrophilic characteristics, so that when the yarn is formed into a fabric to be utilized as a substrate, the substrate has the unique feature of bonding the vinyl sheet material to a selected surface utilizing conventional water base glues, which vinyl sheet material is otherwise not receptive to said glues.
The first step in accomplishing the invention is best shown in Figures 1 and ~, wherein the textured, continuous, multi-filament, polymeric yarn 10 of Figure 1 has incorporated the aforesaid surfactant thereinto.
The yarn may be formed of several types of polymeric filaments, e.g. polyester and nylon; however, for pur-poses of describing the present invention, polyester has been selected, applied, and tested. Thus the tex-tured yarn 10 of Figure 1 is formed of continuous polyester filaments. It is contemplated that the tech~
13~77~
nique of the present invention would also be ~pplicable to blended yarns, formed predominantly o~ spun poly-meric staple if desired, however, such yarns forms have not been actually tested. It is possible such yarns might have sufficient hydrophilic characteristics because of their surface configuration. If not, however, the teaching of the present invention would be applicable.
In Figure 2, there is illustrated schematically a conventional texturing process in which the multi-filament yarn 10 is passed through a texturing appara-tus 12, which apparatus may utilize any of the conventional texturing processes such as false twist texturing, air jet texturing, stuffer box texturing, edge crimping, gear crimping, and the like. After passing through the texturing apparatus 12, a guide system 1~ directs the yarn 10 over a kiss roll 20, which kiss roll 20 is partially submerged in a trough 16 containing the surfactant 18 to be explained hereinafter. A second guide system 22 directs the chemically treated yarn along to a takeup package 2~.
The chemical itself is a surfactant having certain characteristics or parameters. Since one of the objects of the yarn is to be processed by a water jet loom, the treated yarn will be rewet during the weaving operation. Thus the surfactant must be able to withstand the water from the water jet loom and not be washed out during weaving. Therefore, while the sur-factant should be water dispersible (to enhance disper-sion into the interfilamentary structure of the yarn,it should not be water soluble). Secondly, in order to be receptive to the water based glue the surfactant should have hydrophilic lipophilic bonding charac-teristics such that the HLs factor falls in the range of 7-10. Naturally the surfactant must be compatible with conventional wallcovering glues.
In order to be water dispersible into the inter-filamentary structure of the yarn 10, the sur~actant must have a viscosity in the range of 50-100 Saybolt Universal Seconds (SUS) depending on the yarn.
Finally, since the substrate into which the yarn is woven will be embedded into the vinyl wallcovering during an operation involving heat and pressure, the surfactant must be able to withstand temperatures above a prescribed level. Therefore, the smoke point of the surfactant must be above 350F. One surfactant which has been selected and which has tested satisfactorily has an ethoxylated alkyl ary]. alcohol base.
Specifically the surfactant selected and tested is Lurol 2405 by George A. Goulston, Inc. of Monroe, North Carolina.
The selected surfactant is preferably introduced to the yarn during the texturing process as described and illustrated in Figure 2. Alternatively, the surfactant ! could be applied to the yarn in a separate operation;
while the yarn is on the yarn package; or even after the yarn is woven into the gauze fabric. When intended for use as a substrate for wallcovering, specifications require that a wallcovering be able to e~hibit a 0.35 pound pull strength. Tests have shown that the use of quantities of surfactant in the range of 1.1% by weight of yarn are inadequate to achieve the 0.35 pound pull strength. As a matter of fact, a quantity of 1.1% by weight of surfactant to yarn results in a pull strength of only 0.18 pounds. On the other hand surfactant in amounts of 3% by weight have achieved a pull strength of 0.5 pounds. Therefore, it is believed that surfac-tant in the amount of at least 2.5~ by weight of sur-factant to yarn will be adequate to achieve the 0.35 pound pull strength requirement. In actuality, the weight of the polyester yarn processed was 159 denier ~77Q~
prior to the addition of the additive. In order to achieve the 3~ additive, the speed of the kiss roll 20 was controlled until the yarn denier of the yarn after treatment reached 164.
The application of the surfactant swells the ori-fices (called dye sites) in the textured, multi-filament polyester yarn. The surfactant causes the glue to spread evenly across the surface o~ all filaments to the extent that the glue will bond the polyester fila-ments to the wall surface. Use of the surfactant allows the polyester to beco~e wet and increases the tendency of the surfactant to enter the interfilamen-tary structure of the yarn. Then when the glue or adhesive is applied to the yarn after it is woven into the gauze substrate and embedded in the surface of the wallcovering, the glue adheres to the entire surface of the yarn filaments and actually bonds the substrate to the wall surface. Since the substrate is embedded in the rear surface of the wallcovering, the wallcovering is thus caused to adhere to the wall. Actually the vinyl wallcovering is not, in and of itself glued to the wall, rather the substrate is glued to the wall.
The treated yarn referred to hereinabove is formed into the gauze structure illustrated in Figure 3. The weaving operation is preferably carried out on a fluid jet loom (water or air).
The gauze substrate 30 illustrated in Figure 3 is embedded into the vinyl wallcovering or sheet material 40 as best illustrated in Figure 4. Once the molten vinyl is extruded into sheet material 40 (Figure 4), it is joined to the gauze 30 which is being fed by a feed roll 32. The vinyl sheet material 40 and gauze 30 con-tinue in contiguous arrangement through a pair of calendar rolls 44,46 where the gau7e is caused to be embedded into the underneath surface of the sheet ~3~77~
material 40. The calendar rolls ~l4,~6 are maintained at a temperature of appro~imately 350F. The upper calendar roll 44 may be provided with an embossed pat-tern to decorate the front surface of the vinyl sheeting 40, if desired.
In Figure 5, there is illustrated the completed construction which includes the vinyl wallcovering 40 having the gauze 30 embedded therein joined to a wall surface 50 by a conventional water base glue 52.
Examples of conventional water based wallcovering glues include GT-12 and GT-~60A produced by ~oman Adhesives, Inc. of ~loomfield, New ~ersey. As stated previously, when the glue is applied to the rear surface of the wallcovering ~0 it mechanically affixes to the gauze substrate 30 embedded in the rear surface thereof and bonds the substrate 30 to the surface of wall 50. The moisture in the glue is absorbed into the surfactant clinging to the gauze, and when dry, the glue mechani-cally bonds the gauze to the wall.
In Figure 6, the entire process is summarized.
While the yarn has been described herein as being used in the formation of a gauze substrate for wallcoverings, the yarn itself may have other significant utilization.
To the knowledge of applicant, the yarn of the present ~5 invention is the first incident of a polymeric yarn (hydrophobic characteristics) being modified in the yarn form by the use of a surfactant additive to have hydrophilic characteristics. Secondly, the gauze substrate may have application in other environments than the cited examples of wallcoverings. The gauze substrate oE the present invention permits a hydrophilic gauze to be woven more economically on a water jet loom.
The resulting polyester or polymeric gauze, as a result of the present invention, can then be embedded in a vinyl sheet material which can then be bonded to any desired surface, ~3177~
There has been described in detail hereinabove a preferred embodiment of the present invention. Some modifications have been cited specifically. Other modifications may come to mind. The present invention should be limited only by the following claims.
Claims (29)
1. An improved wallcovering comprising:
a) a vinyl sheet material having a front decorative surface and a rear surface;
b) a gauze substrate affixed to said rear surface of said sheet material;
c) said gauze substrate formed pri-marily of a textured, continuous, multi-filament, polymeric yarn having a surfactant incorporated into the interfilamentary structure thereof;
d) said surfactant having the following characteristics:
i) water dispersible and water insoluble;
ii) HLB factor in the range of 7-10;
iii) heat stable to at least 350°F.
a) a vinyl sheet material having a front decorative surface and a rear surface;
b) a gauze substrate affixed to said rear surface of said sheet material;
c) said gauze substrate formed pri-marily of a textured, continuous, multi-filament, polymeric yarn having a surfactant incorporated into the interfilamentary structure thereof;
d) said surfactant having the following characteristics:
i) water dispersible and water insoluble;
ii) HLB factor in the range of 7-10;
iii) heat stable to at least 350°F.
2. The improved wallcovering according to claim 1 wherein the viscosity of said surfactant is in the range of 50-100 SUS.
3. The improved wallcovering according to claim 1 wherein said gauze substrate is embedded in said rear surface.
4. The improved wallcovering according to claim 1 wherein said yarn is 100% polyester.
The improved wallcovering according to claim 1 wherein said yarn is 100% nylon.
6. The improved wallcovering according to claim 1 wherein said surfactant has an ethoxylated alkyl aryl alcohol base.
7. The improved wallcovering according to claim 1 wherein. said surfactant is present in said gauze in an amount of at least 2.5% surfactant to yarn weight.
8. The improved wallcovering according to claim 1 wherein said surfactant is present in an amount of at least 3% surfactant to yarn weight.
9. Improved gauze formed primarily of textured, continuous, multi-filament, polymeric yarns having a surfactant incorporated into the interfilamentary structure thereof; said surfactant having the charac-teristics of:
a) being water dispersible and water insoluble;
b) having an HLB factor in the range of 7-10; and c) being heat stable to at least 350°F.
a) being water dispersible and water insoluble;
b) having an HLB factor in the range of 7-10; and c) being heat stable to at least 350°F.
10. The gauze according to claim 9 wherein the viscosity of said surfactant is in the range of 50-100 SUS .
11. The gauze according to claim 9 wherein said polymeric yarn is 100% polyester.
12. The gauze according to claim 9 wherein said polymeric yarn is 100% nylon.
13. The gauze according to claim 9 wherein said surfactant has an ethoxylated alkyl aryl alcohol base.
14. The gauze according to claim 9 wherein said surfactant is present in said gauze in an amount of at least 2.5% surfactant to yarn weight.
15. The gauze according to claim 9 wherein said surfactant is present in an amount of at least 3% sur-factant to yarn weight.
16. A process for forming a polymeric gauze material having hydrophilic characteristics comprising the steps of:
a) texturizing a continuous, multi-filament, polymeric yarn;
b) applying a surfactant having the characteristics of being 1) water dispersible and water insoluble; 2) having an HLB factor in the range of 7-10; 4) being heat stable to at least 350°F. to said yarn downstream of the texturizing operation; and c) weaving the yarn as treated by step (b) into a gauze fabric on a fluid jet loom,
a) texturizing a continuous, multi-filament, polymeric yarn;
b) applying a surfactant having the characteristics of being 1) water dispersible and water insoluble; 2) having an HLB factor in the range of 7-10; 4) being heat stable to at least 350°F. to said yarn downstream of the texturizing operation; and c) weaving the yarn as treated by step (b) into a gauze fabric on a fluid jet loom,
17. The process according to claim 16 wherein the viscosity of said surfactant is in the range of 50-100 SUS .
18. The process according to claim 16 wherein said yarn is 100% polyester.
19. The process according to claim 16 wherein said yarn if 100% nylon.
20. The process according to claim 16 wherein said surfactant has an ethoxylated alkyl aryl alcohol base.
21. The process according to claim 16 wherein said surfactant is present in said gauze in an amount of at least 2.5% surfactant to yarn weight.
22. The process according to claim 16 wherein said surfactant is present in an amount of at least 3% sur-factant to yarn weight.
23. Polymeric yarn with hydrophilic charac-teristics comprising a textured, continuous, multi-filament, polymeric yarn having a surfactant incorporated into the interfilamentary structure thereof, said surfactant having the following characteristics:
a) being water dispersible and water insoluble;
b) an HLB factor in the range of 7-10;
c) heat stable to at least 350°F.
a) being water dispersible and water insoluble;
b) an HLB factor in the range of 7-10;
c) heat stable to at least 350°F.
24. The yarn according to claim 23 wherein the viscosity of said surfactant is in the range of 50-100 SUS.
25. The yarn according to claim 23 and further being 100% polyester.
26. The yarn according to claim 23 and further being 100% nylon.
27. The yarn according to claim 23 wherein said surfactant has an ethoxylated alkyl aryl alcohol base.
28. The yarn according to claim 23 wherein said surfactant is present in said gauze in an amount of at least 2.5% surfactant to yarn weight.
29. The yarn according to claim 23 wherein said surfactant is present in an amount of at least 3% sur-factant to yarn weight.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/146,968 US4925726A (en) | 1988-01-22 | 1988-01-22 | Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristics |
| US146,968 | 1988-01-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1317705C true CA1317705C (en) | 1993-05-18 |
Family
ID=22519797
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000576856A Expired - Fee Related CA1317705C (en) | 1988-01-22 | 1988-09-08 | Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristics |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4925726A (en) |
| EP (1) | EP0325028B1 (en) |
| AT (1) | ATE86317T1 (en) |
| CA (1) | CA1317705C (en) |
| DE (1) | DE3878883D1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5481904A (en) * | 1994-09-28 | 1996-01-09 | The United States Of America As Represented By The Secretary Of The Navy | Oil spillage detector |
| US6211099B1 (en) | 1998-07-21 | 2001-04-03 | American Fiber & Finishing Sc, Inc. | Substrate fabric |
| US6238441B1 (en) | 1998-07-29 | 2001-05-29 | Burlington Industries, Inc. | Hydrophilic yarn dyed polyester process |
| EP1250481A1 (en) * | 2000-01-21 | 2002-10-23 | American Fiber & Finishing S.C., Inc. | Texturized fabrics |
| US7565920B2 (en) * | 2003-11-07 | 2009-07-28 | The Hong Kong Polytechnic University | Woven fabric with moisture management properties |
| DE102006033803A1 (en) | 2006-03-06 | 2007-09-13 | Ewald Dörken Ag | Railway, in particular for use in the construction sector |
| US20070287345A1 (en) * | 2006-06-09 | 2007-12-13 | Philip Confalone | Synthetic nonwoven wallcovering with aqueous ground coating |
| CN101818551B (en) * | 2009-02-27 | 2011-09-28 | 北京新丽美盛典装饰材料有限公司 | Wall cloth |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2982680A (en) * | 1960-04-18 | 1961-05-02 | Kimberly Clark Co | Cellulosic product |
| FR93832E (en) * | 1967-01-13 | 1969-04-14 | Jacques Gustave Henri Dupriez | Primed elastic textile used as a support or reinforcement for bridging joints or surface coverings. |
| US3788941A (en) * | 1969-10-31 | 1974-01-29 | Grace W R & Co | Removable floor and wall surface coverings |
| US3795567A (en) * | 1971-08-27 | 1974-03-05 | Winfield Design Ass Inc | Aluminum foil wall covering |
| FR2429101A1 (en) * | 1978-06-19 | 1980-01-18 | Dycem Ltd | COMPOSITE SHEET MATERIAL AND METHOD OF USE FOR PROTECTION AGAINST POLLUTION FROM DUST AND / OR BACTERIA |
| GB2054472B (en) * | 1979-06-23 | 1984-02-15 | Johnson J F J | Covering surfaces with sheet material |
| DE3233848A1 (en) * | 1982-09-11 | 1984-03-15 | Henkel KGaA, 4000 Düsseldorf | MAKULATURE WITH A DEHAESIVALLY ADJUSTED SURFACE FOR WALLPAPERS OF ALL TYPES AND HEAVY WALLS |
| US4460643A (en) * | 1983-02-07 | 1984-07-17 | The Dexter Corporation | Nonwoven fibrous backing for vinyl wallcover |
| US4555441A (en) * | 1985-03-06 | 1985-11-26 | Stik-Trim Industries, Incorporated | Self-adhesive wall covering or the like and method of making same |
| DE3536319A1 (en) * | 1985-10-11 | 1987-04-16 | Freudenberg Carl Fa | Covering nonwoven for absorbent sanitary disposable articles |
| US4806254A (en) * | 1987-05-26 | 1989-02-21 | Colgate-Palmolive Co. | Composition and method for removal of wrinkles in fabrics |
-
1988
- 1988-01-22 US US07/146,968 patent/US4925726A/en not_active Expired - Fee Related
- 1988-09-08 CA CA000576856A patent/CA1317705C/en not_active Expired - Fee Related
- 1988-11-10 AT AT88310568T patent/ATE86317T1/en not_active IP Right Cessation
- 1988-11-10 DE DE8888310568T patent/DE3878883D1/en not_active Expired - Lifetime
- 1988-11-10 EP EP19880310568 patent/EP0325028B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| EP0325028B1 (en) | 1993-03-03 |
| ATE86317T1 (en) | 1993-03-15 |
| EP0325028A2 (en) | 1989-07-26 |
| EP0325028A3 (en) | 1990-05-09 |
| US4925726A (en) | 1990-05-15 |
| DE3878883D1 (en) | 1993-04-08 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA1212844A (en) | Flexible backing material for use in coated abrasives | |
| US3528874A (en) | Heat-insulating fabric and method of preparing it | |
| CA1162445A (en) | Water-proof, fuse-bonding fabric | |
| EP0062259B1 (en) | Multilayer composite sheet useful as a substrate for artificial leather | |
| CA1302067C (en) | Composite sheet for artificial leather and method for its production | |
| US4656080A (en) | Waterproof composite sheet material | |
| US3616133A (en) | Heavy-duty wipe | |
| CA1317705C (en) | Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristics | |
| US4634612A (en) | Decorative ribbon and sheet material | |
| GB1443131A (en) | Fibrous sheet material and method for producing same | |
| EP2006439B1 (en) | Artificial leather and method for producing the same | |
| US20040170799A1 (en) | Heat-insulating material and method of making the same | |
| EP0118221A2 (en) | Nonwoven fibrous backing for vinyl wallcover | |
| US4874019A (en) | Wallcovering substrate formed of textured, continuous, multi-filament yarns having hydrophilic characteristics | |
| EP0416660A2 (en) | Reinforced film and method of manufacturing same | |
| US5256429A (en) | Composite sheet for artificial leather | |
| US4225321A (en) | Heat set and destretched polyester backing material in coated abrasive manufacture | |
| US4478610A (en) | Method of preparing flexible backing material for use in coated abrasives | |
| US3075274A (en) | Method of making and finishing papermaker's felts | |
| US5006399A (en) | Planar textile structure | |
| CA1062022A (en) | Non-polluting waterproof cloth finish for abrasive cloth | |
| US2368948A (en) | Process for increasing the transparency of fabrics containing filament yarns | |
| US3250662A (en) | Coated fabric | |
| US5043208A (en) | Continuous multi-filament polyester substrate readily adherable to a vinyl sheet | |
| CA1325926C (en) | Foam saturation and release coating of a fibrous substrate |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |