JPH0152511B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of making foam back drapery fabrics and fabrics so made. Foamback fabrics have many uses, especially as draperies. Foamback Drapery fabric provides all of the light blocking properties of conventional lined Drapery at a fraction of its cost.

Traditionally, in the production of foam-backed drappery cloth, the foam is crushed after being applied.
It was then necessary to cure. Without crushing, foam buckling does not have the anti-abrasion properties necessary to be effective as a drapery fabric.
Although conventional foam drapery fabrics are generally suitable, they do not have optimal textile-like feel, drape, or appearance properties. Although it is known that embossing can improve the fiber-like properties of foam backing (US Pat. No. 3,527,654), embossing has not typically been utilized in the construction of foam backing drapery fabrics. Also, the embossed pattern could not be properly secured to last the life of the fabric and provide the desired fiber-like properties.

In accordance with the present invention, a method of making embossed foam back drapery fabrics and fabrics so made are provided that overcome the problems inherent in the prior art. According to the present invention, the embossed pattern during formbacking is properly secured and durable to give the final fabric optimal desirable fiber-like properties. Embossed foam back draperies have a more textile-like texture than simply crushed foam back fabrics, and embossed foam back fabrics have improved softness, drapability, and appearance properties.

According to one feature of the method according to the invention, foam back drapery fabrics are produced from moving textile material. A wet foam backing is applied to the moving fabric, the foam backing is at least partially dried without effectively curing it, and the foam backing is embossed. Water, preferably an aqueous solution containing a release agent and a wetting agent, is then applied to the foam backing to substantially penetrate the foam backing without substantial penetration into the fabric. The foam backing is then cured to produce a final drapery fabric with good feel, abrasion resistance, drape and appearance properties.

According to another feature of the method according to the invention, the foam-backed drapery fabric is fabricated by applying wet cross-linking foam backing to the moving fabric substantially sequentially, and applying the wet foam backing to the moving fabric in a substantially sequential manner. It is produced from a moving fabric by at least partially drying without curing and embossing the foam backing. A predetermined and sufficient amount of moisture, preferably including a release agent and a wetting agent, is then applied to complete the crosslinking of the formbacking.
This secures the embossment, but prevents collapse of the form cell structure, and the embossed foam is returned to the backing and then back hardened.

According to still further features of the method, the foam-backed drapery fabric is formed by applying a wet foam backing to the moving fabric and applying flock to the wet foam backing. dry at least partially without effectively curing the foam backing, emboss the foam backing, and dry the foam backing without substantially penetrating the fabric. Apply an aqueous solution at an impregnation rate of 80% and dry the foam backing,
It is then manufactured by performing a step consisting essentially of curing the foam backing to produce a final drapery fabric with good fiber-like properties.

The aqueous solution has release and wetting agents and preferably also contains a curing catalyst and is applied to the foam backing preferably by kiss coating, but it may also be sprayed.

The final drapery fabric made in accordance with the present invention has an embossed form backing that can recover within 5 seconds to 1 minute after 3000 psi is applied for 5 minutes. Drapery cloth is
Compared to regular foam drape cloth,
It has improved flexibility, textile-like feel, drape and appearance properties.

A primary object of the present invention is to provide foam back drapery fabrics with improved fiber material properties. This and other objects of the invention will be apparent from the detailed description of the invention and from the claims.

With reference to FIG. 1, one example of a method for manufacturing foam back drapery fabrics from a moving fabric F can be easily understood. Fabric F is supplied from a source 10 to a foam application station 12 where a wet foam bucking is applied to the moving fabric. Foam bucking may be applied by coating or other conventional techniques, by defining a liquid foam pillow, passing the fabric F through the foam pillow, and moving only a portion of the foam in the foam pillow through the pillow. It is preferably applied by passing it through the fabric as it passes. Such an arrangement is more fully described in US Pat. No. 4,016,831. The foam may be any suitable cross-linking foam, and may be self-cross-linking and/or may include a cross-linking fiber resin; the self-cross-linking acrylic latex foam and the fiber resin may be preferable.

After applying the foam F' to the surface of the fabric F, the fabric is passed through a flocking station 14. The flocking station 14 is conventional and preferably includes a mechanical flocking module, preferably staple cotton flocking. Floating improves the fiber-like feel properties of the final fabric produced.

After flocking, the web F is then passed through a drying station 16 where it is subjected to form buckling.
F' is at least partially dried without being effectively cured. The drying station 16 may be a conventional tenter dryer, and the drying is carried out at a temperature such that the surface of the foam exiting the drying station 16 is approximately
Preferably, the temperature is 200-240〓.

The fabric web F with the dried form backing F' is then immediately transferred to the embossing station 1.
Proceed to step 8. Formbutting is embossed,
That crushing is imparted, which improves the abrasion resistance of the foam buckling. In addition to form bucking compaction, embossing makes the final fabric produced more flexible, imparts a more fiber-like texture than mere compaction, improves appearance, and generally provides an improved final fabric. The embossing station 18 may include any conventional means, preferably a rubber roller 20 acting on the fabric web, together with a suitable pattern formed on its surface (e.g., a 1/12 inch screen line pattern). A steel roller 19 for embossing is included. Sufficient force to effect embossing (e.g. 8 tons) is applied to the rubber roller, as indicated by arrow 21 in FIG.

FIG. 2 shows a formback fabric according to the invention, the fabric itself being designated F, the formbacking before embossing being designated F', and the embossed formbacking being designated F''.
The right side of FIG. 2 shows the web before passing through the embossing station 18, and the left side shows the web after passing through the embossing station 18.

In order to impart durability to the embossed pattern, according to the invention the embossed foam web F'' is then immediately passed through an aqueous solution application station 22. A suitable release agent (e.g. a silicone emulsion softener) ), an aqueous solution containing a suitable wetting agent and preferably a curing catalyst (e.g. an acid catalyst) is applied here. The release agent prevents the gaps in the unsquashed foam from sticking, and the wetting agent substantially removes the solution. Penetrate the entire foam boxing,
The catalyst then accelerates curing during subsequent processing. Enough solution is applied to penetrate the foam backing without substantial penetration into the fabric, but care must be taken not to apply too much solution as too much solution will collapse the foam cell structure. It has been found that a solution pick-up of 50-80% based on the weight of dry foam solids gives the desired results according to the invention (about 18-25% pick-up based on the weight of the fabric and foam). (20% is optimal). Although we do not know the exact theory explaining why the application of an aqueous solution provides proper fixation of the embossed pattern, the aqueous solution ensures that the necessary cross-linking chemical reaction is completed during formbacking, thereby fixing the embossed pattern. It is thought that this provides sufficient moisture to the dry foam bag.

The step of applying the aqueous solution may be carried out by spraying the aqueous solution onto the foam backing, but it is preferred to apply the aqueous solution by kiss coating. As shown in FIG.
is rotated in a tank 24 containing an aqueous solution 25, and the rotational speed of the roller 23 determines the amount of solution applied to form bucking.

After the aqueous solution application station 22, the foam web is finally passed through a curing station 28. However, if the equipment used in the curing station includes rollers over which the web is passed in the curing oven, it is necessary to provide a pre-drying station 26 or the rollers in the curing oven will be embossed. This will tend to remove the pattern that has been created. Drying station 26 preferably includes an electric quartz infrared pre-dryer, and curing station 28 then includes a conventional curing oven having rollers or the like over which the web is passed. After passing through the curing station 28, the final drapery fabric D is obtained.

Naturally, other conventional processes may be performed on the final drapery fabric D. For example, it may be washed to remove excess floe or to make the texture even softer. The final drapery fabric D produced includes an embossed formback fabric whose formbacking can be recovered within 5 seconds to 1 minute after application of 3000 psi for 5 minutes.
The final fabric has desirable fibrous feel, drape resistance and appearance properties and is highly suitable for use in drapery construction.

EXAMPLE Drapery fabric F consisting of 41% polyester, 58% rayon and 1% acrylic fibers, weighing 0.392 pounds per yard (45 inches wide)
was coated with foam by passing it through a foam pillow. 3.2 dry ounces of foam per yard of length was applied at a wet density of 170 grams/liter. The foam composition included an acrylic polymer, a resin crosslinker, a blowing agent, a cell stabilizer, a filler material, and a pigment. After applying the wet foam, the fabric entered a mechanical flocking module where approximately 0.5 ounces of staple cotton flock per yard of length was applied to the wet foam. Processing speed during the entire process was approximately 40 yards/minute.

After passing through the mechanical flocker 14, the formback web passes through a tenter dryer 16 having a first drying zone of 275 meters and a second and third drying zone of 320 meters each.
I attended. Next, the fabric is embossing station 1.
8, where an embossing roller with a 1/12 inch screened line pattern was brought into contact with the foam backing while a force 21 of 8 tons was applied to the rubber roller 20. The embossed foam fabric was then passed through a water pick-up station. Aqueous solution 25 contained 1% silicone emulsion softener (60% active), 0.1% ethoxylated alcohol wetting agent, and 0.08% p-toluenesulfonic acid catalyst. The speed of rotation of roller 23 was controlled relative to the processing speed of the web so that the aqueous solution was applied at 60% pick-up and penetrated the foam backing without substantial penetration into the fabric. The web is then passed through an electric quartz infrared pre-dryer 26 and then through a 140 yard long conventional roller curing oven at a temperature of 320
〓 was held. The final fabric D produced had excellent fiber-like feel, softness, drapability, and appearance properties. For form bashing
When a force of 3000 psi was applied for 5 minutes, bucking recovered in less than 1 minute.

From the foregoing, it can be seen that, in accordance with the present invention, there is provided an improved method for making foam back drapery fabrics and fabrics so made, including durable embossments that are capable of rapid recovery. Patterned packing has high abrasion resistance, foam packing texture,
Improved flexibility and fiber-like appearance. While the invention has been shown and described in what is presently believed to be a practical and preferred embodiment, it will be obvious to those skilled in the art that many modifications may be made within the scope of the invention. Will.

[Brief explanation of drawings]

FIG. 1 is a schematic diagram showing the sequence of steps for carrying out an example of the method according to the present invention, and FIG. 2 is a perspective view showing a part of the formed back drapery cloth according to the present invention. 12... Form application station, 13...
Floating station, 16... Drying station, 18... Embossing station, 22...
...Aqueous solution application station, 28...Curing station.

Claims (1)

Claims: 1. A method of producing foam backing draperies from a moving fabric, comprising the steps of: (a) applying a wet crosslinkable foam backing to the moving fabric; (b) at least partially drying the wet foam backing without effectively curing; (c) embossing the foam backing; (d) applying a foam backing to the embossed foam backing; (e) returning a predetermined amount of moisture sufficient to complete the crosslinking of the king, thereby securing the embossment but preventing collapse of the form cell structure; and (e) having the desired fiber properties. A method comprising the steps of completing the crosslinking and curing the foam backing to obtain the final drapery fabric. 2 Step (d) uses an aqueous solution containing a stripping agent and a wetting agent,
2. A method according to claim 1, which is carried out by applying foam bagging at an impregnation rate of about 50 to 80% based on the weight of dry foam solids. 3. Step (e) is carried out in a curing oven having rollers over which the formback fabric is advanced, and furthermore, between steps (d) and (e) (d1) the embossing is removed in the curing oven. 2. A method as claimed in claim 1, including the step of drying the foam bag before proceeding into a curing oven to prevent it from forming. 4. The method of claim 1 further comprising the step of (a1) immediately after step (a) applying a flock to the wet foam backing.