THERMALLY FIXABLE TEXTILE FABRIC

Abstract

A thermally fixable textile fabric, particularly useful as a fixable interlining, lining, and/or outer fabric in a textile industry, includes: a carrier material comprising a melt-blown non-woven fabric. The carrier material has flock fibers on one side and a hot-melt adhesive on a side facing away from the flock fibers.

Claims

1. A thermally fixable textile fabric, particularly useful as a fixable interlining, lining, and/or outer fabric in a textile industry, comprising: a carrier material comprising a melt-blown non-woven fabric, wherein the carrier material has flock fibers on one side and a hot-melt adhesive on a side facing away from the flock fibers.

2. The textile fabric according to claim 1, wherein the textile fabric comprises a web material fabric.

3. The textile fabric according to claim 1, wherein the textile fabric has a breathability, measured according to DIN EN ISO 9237 at 100 Pa, of more than 20 l/m2s.

4. The textile fabric according to claim 1, wherein the textile fabric has an elasticity, measured according to DIN EN ISO 13934-1 at a force of 3 N, in at least one direction of at least 2%.

5. The textile fabric according to claim 1, wherein the hot-melt adhesive is selected from the group consisting of thermoplastic polymers, comprising polyamides, copolyamides, polyesters, copolyesters, ethyl vinyl acetate, and its copolymers, polyethylene, polypropylene, amorphous polyalphaolefins, polyurethanes, and mixtures thereof.

6. The textile fabric according to claim 1, wherein the flock fibers are fixed on the carrier material by an adhesive.

7. The textile fabric according to claim 1, wherein the flock fibers only partially cover the carrier material.

8. The textile fabric according to claim 1, wherein the textile fabric has a surface weight, measured according to DIN EN 29073, in a range of 10 g/m.sup.2 to 400 g/m.sup.2.

9. The textile fabric according to claim 1, wherein the textile fabric has a thickness according to DIN EN ISO 9073-2 of 0.5 mm to 1.6 mm.

10. The textile fabric according to claim 1, wherein the textile fabric has a module as measured in accordance with DIN 53 835 at a stretching of 25% of less than 20 N.

11. A method of using the textile fabric according to claim 1 as a fixable interlining, lining, and/or outer fabric in the textile industry.

12. A method for producing the textile fabric according to claim 1, comprising the following steps: A) providing the carrier material comprising the melt-blown non-woven fabric; B) applying flock fibers to one side of the carrier material; C) applying the hot-melt adhesive to the side of the carrier material facing away from the flock fibers.

13. The method according to claim 12, wherein a provision of the carrier material in step A) comprises fixing the carrier material on an auxiliary carrier and the auxiliary carrier is removed after application of the flock fibers in step B).

14. The method according to claim 12, wherein the application of the flock fibers in step B) comprises an upstream step of applying an adhesive.

15. The method according to claim 12, wherein method step C) is carried out before method step B).

16. The textile fabric according to claim 3, wherein the breathability is from 20 l/m2s to 2000 l/m2s.

17. The textile fabric according to claim 3, wherein the breathability is less than 10 l/m2s.

18. The textile fabric according to claim 7, wherein the flock fibers form a regular or irregular pattern.

19. The method according to claim 13, wherein the auxiliary carrier comprises a spunbond non-woven.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:

[0016] FIG. 1: Textile fabric 1 with full-surface flock fiber coating

[0017] FIG. 2: Textile fabric 1 with a flock fiber coating designed as a pattern

[0018] FIG. 3: Photograph of the surface of a textile fabric 1 with a flock fiber coating formed as a pattern

DETAILED DESCRIPTION

[0019] In an embodiment, a task of the present invention is to at least partially eliminate the aforementioned disadvantages.

[0020] In an embodiment, this task is achieved by a thermally fixable textile fabric, particularly usable as a fixable interlining, lining and/or upper fabric in the textile industry, comprising a carrier material based on a melt-blown non-woven fabric, wherein the carrier material has flock fibers on one side and a hot-melt adhesive on the side facing away from the flock fibers.

[0021] The advantage of the textile fabric according to the invention is that it can be produced in a simple manner in the form of web material fabric having flock fibers. In a preferred embodiment of the invention, the textile fabric is therefore designed as a web material fabric. A major advantage over clothing that has been flocked in the ready-made state is that the use of flocked web material enables the clothing manufacturer to produce flocked fiber surfaces on a garment only by cutting and fusing, without having to use complex flocking technologies.

[0022] It is further advantageous that the breathability can be achieved in a simple manner by the use of different density levels of the melt-blown non-woven fabric. In the subsequent flocking process, the adhesive can then be applied to the melt-blown fibers, leaving the areas between them free and serving as breathing (air-permeable) pores.

[0023] According to the invention, the textile fabric comprises a carrier material based on a melt-blown non-woven fabric. The term based on means at least 90% by weight, based on the total weight of the carrier material. The term melt-blown fibers is understood to mean fibers according to the invention which are produced by extruding a molten thermoplastic material through a plurality of fine, usually circular, nozzle capillaries as molten fibers into a high velocity gas (for example air). This procedure reduces the diameter of the fibers. Thereafter, the melt-blown fibers are carried by the high velocity gas stream and deposited on a collection surface to form a melt-blown non-woven fabric of randomly distributed fibers. The melt-blowing process is well known and described in various patents and publications, for example, NRL Report 4364, Manufacturing of Superfine Organic Fibers by V. A. Wendt, E. L. Boone and C. D. Fluharty; NRL Report 5265 An Improved Device for the Formation of Superfine Thermoplastic Fibers by K. D. Lawrence, R. T. Lukas and J. A. Junge, and the U.S. Pat. No. 3,849,241, issued on Nov. 19, 1974 to Buntin, et al. These publications are hereby included by reference.

[0024] A further advantage of a melt-blown non-woven fabric is that, due to the many fine fibers, the bonding of an adhesive is significantly better than in the case of conventional non-wovens.

[0025] In a preferred embodiment of the invention, the melt-blown fibers are formed from polymers selected from the group consisting of: polyesters, polyolefins, polyamides, polyacrylates, polyvinyl acetates and also polyurethanes, copolymers and/or mixtures thereof. Polyurethanes are particularly preferred, since they have a particularly high elasticity. Also preferred are thermoplastic elastomers, especially thermoplastic elastomeric polyesters, polyolefins and/or polyurethanes. Thermoplastic elastomers (TPE, sometimes also called elastoplasts) are plastics which behave at room temperature comparable to the classic elastomers, but can be plastically deformed under the application of heat and thus exhibit a thermoplastic behavior.

[0026] In a further preferred embodiment of the invention, the melt-blown fibers have a fiber titer of 0.2-5 dtex, preferably 0.5-3 dtex, in particular 0.5-2 dtex.

[0027] The proportion of melt-blown fibers in the textile fabric is preferably at least 10% by weight, more preferably from 20% by weight to 60% by weight, in particular from 25% by weight to 55% by weight, in each case based on the total weight of the textile fabric.

[0028] According to the invention, the carrier material has flock fibers on one side. Flock fibers are low-length fibers that are applied in the form of loose fibers to a substrate, here the carrier material. Depending on the fiber strength and length, a light-soft to hard-abrasive surface can be produced according to the desired function, optics or haptics. The flock fibers may be formed from any natural or synthetic material. Synthetic materials preferably comprise nylon, polyamide, polyesters, for example terephthalate polymers, and natural materials such as cotton, silk, viscose and/or wool.

[0029] The length of the flock fibers can be varied as desired. The flock fibers preferably have a length in the range from 0.3 mm to 1.5 mm, preferably from 0.4 mm to 0.75 mm, in particular from 0.4 mm to 0.6 mm.

[0030] The titer of the flock fibers can also be varied as required. The flock fibers preferably have a titer in the range from 0.5 dtex to 3 dtex, preferably from 0.9 dtex to 1.7 dtex, in particular from 0.9 dtex to 1.3 dtex.

[0031] Further, the flock fibers may be linear or non-linear. For example, the flock fibers can be rolled, crimped and/or bent. The flock fibers are preferably substantially perpendicular to the carrier material. Alternatively, however, they can also be arranged randomly, angled and/or substantially parallel. The fibers used for the flocking can be made by cutting filaments to a desired length. The fiber ends produced by the cutting can be smooth or not smooth, for example serrated.

[0032] The flock fibers are preferably fixed to the carrier material by means of an adhesive. Suitable adhesives are, for example, adhesives based on acrylate, polyurethane, silicone and/or rubber. The term based on means a proportion of at least 50% by weight. Adhesives based on acrylate, polyurethane and/or silicone are particularly preferred according to the invention. Suitably, the adhesive is a curable adhesive.

[0033] In a preferred embodiment, the adhesive comprises a crosslinker. The adhesive in the textile sheet is preferably crosslinked by the crosslinker. A preferred crosslinker is a blocked isocyanate. According to its conventional meaning, the term blocked isocyanate describes the fact that the isocyanate is present as an addition compound with a blocking agent, in particular alcohols (urethanes) and/or amines (ureas), when brought into contact with the adhesive. This addition compound can release the isocyanate again at higher temperatures, whereby crosslinking of the adhesive can be initiated.

[0034] The time of crosslinking can be adjusted in a targeted manner by using the blocked isocyanate. Crosslinking can hereby be prevented from already occurring during the coating process, which could lead to imperfections in the coating. A customized degree of crosslinking can also be set by using a blocked isocyanate. This leads to an improved quality of the adhesive.

[0035] Particularly preferred blocking agents according to the invention are selected from the group consisting of 3,5-dimethylpyrazole (DMP), acetoacetic acid, malonic ester, butanone oxime, secondary amines, caprolactam, phenols, alcohols and mixtures thereof. Very particular preference is given here to DMP, since it leads to excellent crosslinking of the polymers, is nontoxic and deblocks even at low temperatures around 120 C. to 130 C.

[0036] The isocyanate may be present in blocked form in one or a plurality of isocyanate groups.

[0037] In one embodiment, the adhesive is crosslinked only by means of isocyanate.

[0038] However, it is also conceivable that the adhesive is crosslinked as an alternative or in addition to the isocyanate by means of other crosslinking agents, for example aziridines, polyisocyanates, carbodiimides, saccharides, acrylic amides, epooxides, amines, oxazolines, urea derivatives, hydrazines and/or carboxylic acid hydrazides.

[0039] Thermally crosslinked adhesives are preferred. These are advantageous over moisture-crosslinked adhesives, since the crosslinking can be controlled in a targeted manner.

[0040] In a particularly preferred embodiment, the textile fabric comprises a melt-blown non-woven fabric based on thermoplastic TPU, polyester, polyamide, polyacrylate, polyvinyl acetate, polyolefins, cotton, wool, viscose, lyocell in combination with flock fibers based on polyamide, polyester, polyacrylate, polyvinyl acetate, polyolefins, cotton, silk, wool and/or viscose, a hot-melt adhesive based on polyamide, polyester, polyolefins, polyacrylates, polyvinyl acetates or polyurethanes and a crosslinked adhesive based on polyacrylate, polyurethane, polyvinyl acetate, rubber and/or silicone.

[0041] Here, based on means in each case a weight fraction of more than 50% by weight.

[0042] In order to obtain a good elasticity (stretching) of the textile fabric, it is advantageous if the elastic resetting of the adhesive is not lower than the elastic resetting of the carrier material.

[0043] In a preferred embodiment, the textile fabric according to the invention has an elasticity, measured according to DIN EN ISO 13934-1 at a force of 3N, in at least one direction of at least 2%, for example from 2% to 50%, more preferably from 10% to 20%.

[0044] In a preferred embodiment, the textile fabric according to the invention has a permanent stretching, measured in accordance with DIN 53 835, in at least one direction of at least 0.1%, for example from 2% to 20%, more preferably from 1% to 5%.

[0045] The flock fibers can cover the carrier material over the entire surface or only partially. If only partial coverage of the substrate material is present, the flock fibers can form a solid or non-contiguous pattern. The only partial covering of the carrier material is advantageous in that the air permeability or breathability of the textile fabric can be adjusted in a simple manner. In addition, it also enables a targeted adjustment of module and stretching behavior.

[0046] In one embodiment of the invention, the textile fabric has breathability as measured in accordance with DIN EN ISO 9237 at 100 Pa of more than 20 l/m2s, for example from 20 l/m2s to 2000 l/m2s. In other embodiments, it may be desirable for breathability to be less, for example less than 20 l/m2s, more preferably less than 10 l/m2s, more preferably less than 5 l/m2s, and especially about 0 l/m2s.

[0047] The flock fibers can be applied to the carrier material by various methods, for example by electrostatic and/or mechanical flocking.

[0048] According to the invention, electrostatic flocking is preferred. This is well known and uses loose flock fibers which are applied in an electric field to the carrier material coated with an adhesive.

[0049] According to the invention, the carrier material has a hot-melt adhesive on the side facing away from the flock fibers. Hot-melt adhesives, also referred to as hot-setting adhesives, hot adhesives or hot-melts, have long been known. Generally, they are understood to mean substantially solvent-free products which, in the molten state, are applied to an adhesive surface, set rapidly on cooling and thus rapidly build up strength. According to the invention, thermoplastic polymers such as polyamides (PA), copolyamides, polyesters (PES), copolyesters, ethyl vinyl acetate (EVA) and their copolymers (EVAC), polyolefins, in particular polyethylene (PE), polypropylene (PP), amorphous polyalphaolefins (APAO), polyurethanes (PU) and mixtures thereof are used as hot-melt adhesives. Particularly preferred according to the invention are copolyamides, copolyesters and polyurethanes.

[0050] In principle, the adhesive effect of the hot-melt adhesives is based on the fact that they can be reversibly fused as thermoplastic polymers and, as a liquid melt, are able, on account of their viscosity lowered by the melting process, to wet the surface to be adhesively bonded and thereby form adhesion thereto. As a result of the subsequent cooling, the hot-melt adhesive sets again to form the solid which has high cohesion and in this way produces the bond to the adhesive surface. After the adhesion has taken place, the viscoelastic polymers ensure that the adhesion is maintained, even after the cooling process, with its volume changes and the associated buildup of mechanical stresses. The cohesion established provides the bonding forces between the substrates.

[0051] In one embodiment, the hot-melt adhesives are used in powder form. The size of the particles is based on the surface to be printed, for example the desired size of a binding dot. In the case of a dot pattern, the particle diameter may vary between >0 m and 500 m. In principle, the particle size of the hot-melt adhesive is not uniform but follows a distribution, i.e., a particle size range is always present. The particle size is expediently matched to the desired application quantity, dot size and dot distribution.

[0052] Hot-melt adhesives in powder form can be applied by means of scattering application, which is expedient in particular for adhering porous substrates for the production of overall breathable textile composites. A further advantage of the scattering application is that it is a simple application method for applications on a large scale. Since thermoactivated powders, for example comprising polyamides, polyesters or polyurethanes, are already adhesive at low temperatures, they are suitable for the gentle lamination of heat-sensitive substrates, for example high-quality textiles. Thanks to good flow properties in the activated state, a good bond is produced even at low pressure and with a short pressing time; however, the risk of penetration into the fabric remains low.

[0053] The hot-melt adhesive can also be applied to the non-woven melt blown fabric by means of paste-printing, double-point and hot-melt processes. The paste-printing method is particularly preferred according to the invention, since in this way grip and elasticity are retained particularly well.

[0054] Due to the use of a melt-blown non-woven fabric as the base material, the basis weight of the textile fabric according to the invention can be set very low. Basis weights, measured according to DIN EN 29073, in the range from 10 g/m.sup.2 to 400 g/m.sup.2, preferably from 25 g/m.sup.2 to 200 g/m.sup.2, and in particular from 30 g/m.sup.2 to 100 g/m.sup.2, have proven to be useful for many applications.

[0055] Moreover preferably, the textile fabric has a thickness according to DIN EN ISO 9073-2 of 0.5 mm to 1.6 mm, preferably from 0.5 mm to 0.9 mm.

[0056] The textile fabric further preferably has a module, measured in accordance with DIN 53 835, with a stretching of 25% of less than 20 N, for example of 1 N to 20 N, preferably of 2 N to 10 N. The comparatively low module of the textile fabric is advantageous because the fabric can be stretched without great force and thus adapts perfectly to the contours of the body.

[0057] Due to its specific properties, the textile fabric according to the invention is outstandingly suitable as a fixable interlining, lining and/or outer fabric in the textile industry. Preferred interlining materials for combination with the non-woven melt-blown fabric of the present invention are selected from knitted or woven elastic fabrics, natural or synthetic yarns, or a combination thereof. These materials may also comprise highly elastic yarns. Preferred lining fabrics for combination with the melt-blown non-woven fabric according to the invention are selected from elastic real leather of animal origin or artificial leather. Preferred outer fabrics for combination with the melt-blown non-woven fabric of the present invention are selected from laminated fabric or loose membranes.

[0058] The invention also relates to a method for producing a thermally fixable textile fabric according to the invention, comprising the following steps: [0059] A) providing a carrier material based on a melt-blown non-woven fabric; [0060] B) applying flock fibers to one side of the carrier material; [0061] C) applying a hot-melt adhesive to the side of the carrier material facing away from the flock fibers.

[0062] An advantage of the method according to the invention is that the melt-blown non-woven fabric can be flocked in the unshaped, i.e. flat, state. The maximum flock fiber density can thereby be achieved.

[0063] The carrier material in step A) can be provided by melt blowing a non-woven raw material, preferably polyurethane. In a preferred embodiment, the carrier material is formed on an auxiliary carrier, for example a spunbond non-woven, thereby giving it a higher stability and easier further processability. The provision of the carrier material therefore preferably comprises its fixing on an auxiliary carrier.

[0064] In one embodiment of the invention, flock fibers are applied to one side of the carrier material in step B). Preferably, the application of the flock fibers comprises the upstream step of applying an adhesive.

[0065] According to the invention, electrostatic flocking is preferred. In this case, the flock fibers are applied in an electric field to the carrier material coated with the adhesive. If an auxiliary carrier is used, adhesives and flock fibers are applied to the side of the carrier material facing away from the auxiliary carrier. The adhesive can be applied by screen printing, spray gun or dip bath. The surface of the carrier material is preferably smooth or only slightly embossed or grooved. The field lines ensure that the flock fibers align at a desired angle, preferably perpendicularly, and thus produce a uniform, textile surface. The adhesive can be cured and the flocking anchored. Excess and unbound flock fibers can be removed by vacuum.

[0066] Mechanical flocking for fastening the flock fibers is also conceivable. For this purpose, the carrier material provided with the adhesive can be guided over a series of, preferably polygonal, rollers, which quickly set them in vibration. This vibration can drive the flock fibers into the adhesive.

[0067] After flocking, the auxiliary carrier, if used, can be removed and a hot-melt adhesive can then be applied to the side of the carrier material facing away from the flock fibers (process step C). The hot-melt adhesive can be applied to the melt-blown non-woven fabric using paste printing, double-point, scattering and hot-melt processes. The paste-printing method is particularly preferred.

[0068] In an alternative embodiment of the invention, method step C) is carried out before method step B).

[0069] The invention therefore also relates to a method for producing a thermally fixable textile fabric according to the invention, comprising the following steps: [0070] A) providing a carrier material based on a melt-blown non-woven fabric; [0071] B) applying a hot-melt adhesive to one side of the carrier material; [0072] C) applying flock fibers to the side of the carrier material facing away from the hot-melt adhesive.

[0073] In a preferred embodiment, the carrier material is formed on an auxiliary carrier, for example a spunbond non-woven. If an auxiliary carrier is used, the hot-melt adhesive is applied to the side of the carrier material facing away from the auxiliary carrier and the latter is removed again before the flock fibers are applied.

[0074] In this method variant too, the application of the flock fibers preferably comprises the upstream step of applying an adhesive.

Example

[0075] Various textile fabrics according to the invention were produced. For this purpose, a carrier material based on a melt-blown non-woven fabric containing a thermoplastic polyurethane with a weight of 75 g/m.sup.2 was provided. The carrier material was produced by means of melt-blown technology and flock fibers (PA 6.6, length 0.4 mm, titer 0.9 dtex) were applied to one side of the carrier material. The flock fibers were fixed on the carrier material by means of various adhesives. The adhesives specified in the table below were used as adhesives. A hot-melt adhesive based on copolyamide was then applied in the form of an aqueous dispersion by means of the rotary screen printing process to the side of the carrier material facing away from the flock fibers.

[0076] The properties of the textile fabrics obtained are shown in the table below:

TABLE-US-00001 TABLE 1 Permanent Wash Example Adhesive Elasticity stretching resistance Result 1 Type 1 * * * good 2 Type 2 ** ** * good 3 Type 3.1 ** *** ** very good 4 Type 3.2 *** ** *** very good

[0077] Explanations of Table 1

1. Adhesive

[0078] Type 1: Water-based acrylate system without crosslinker

[0079] Type 2: Water-based acrylate system with blocked isocyanate crosslinker (requires a deblocking temperature of >140 C.)

[0080] Type 3.1: Acrylate-based water-based system with HDI (hexamethylene diisocyanate) trimer isocyanate crosslinker (requires <120 C. deblocking temperature)

[0081] Type 3.2: water-based PU system with crosslinker (requires <120 C. deblocking temperature)

2. Elasticity

[0082] Elasticity is measured according to DIN EN ISO13934-1:2013. The evaluation is as follows:

[0083] * 25% stretching at a tensile force of 15 N to 20 N

[0084] ** 25% stretching at a tensile force of 10 N to 15 N

[0085] *** 25% stretching at a tensile force of less than 10 N

3. Permanent stretching
The permanent stretching is measured in accordance with DIN 53835. The evaluation is as follows:

[0086] * permanent stretching<3%

[0087] ** permanent stretching 3-4%

[0088] *** permanent stretching 5%

4. Wash resistance
Wash resistance is measured according to DIN EN ISO 6330:2012. The evaluation is as follows:

[0089] * weight loss after 10 washes of 6-7% by weight

[0090] ** weight loss after 10 washes of 3-5% by weight

[0091] *** weight loss after 10 washes of less than 3% by weight

[0092] FIG. 1 shows a thermally fixable textile fabric 1 according to the invention with full-surface flock fiber coating. The textile fabric comprises a carrier material 2 based on a melt-blown non-woven fabric, wherein the carrier material 2 having flock fibers 3 applied to the entire surface and a melt adhesive 4 on the side facing away from the flock fibers 3. The flock fibers 3 are fixed on the carrier material 2 by means of an adhesive 5.

[0093] FIG. 2 shows a thermally fixable textile fabric 1 according to the invention having a flock fiber coating embodied as a pattern. The textile fabric comprises a carrier material 2 based on a melt-blown non-woven fabric, wherein the carrier material 2 having flock fibers 3 applied in the form of a pattern on one side and a hot-melt adhesive 4 on the side facing away from the flock fibers 3. The flock fibers 3 are fixed on the carrier material 2 by means of an adhesive 5.

[0094] FIG. 3 shows a photograph of the surface of a textile fabric 1 with a flock fiber coating formed as a pattern

[0095] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.

[0096] The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article a or the in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of or should be interpreted as being inclusive, such that the recitation of A or B is not exclusive of A and B, unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of at least one of A, B and C should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of A, B and/or C or at least one of A, B or C should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.