Flattened and bonded fabric of foamed vinyl plastisol on a filament core and method of preparing same
AssigneeEngineered Yarns, Inc.
InventorsJames P. Okie, James D. Worrall
Life of this patent
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Abstract
A fabric is prepared from a latent foam-encapsulated filament yarn, the fabric being either woven or non-woven. The fabric is taken to a temperature high enough to activate the foaming agent within the thread under conditions such that thread junctions are bonded together and the thread itself is flattened. The degree of flattening is controlled in order to achieve a selected percentage of open area in the resultant fabric.
Claims39
In a method of producing a fabric of thread, said thread comprising a foamed resin on a core of yarn wherein junctions between threads are bonded together, the improvement comprising, in sequence, the steps of applying a plastisol compound containing an effective amount of a foaming agent therein as a viscous liquid to a filament yarn as a core to encapsulate said yarn, the activation temperature of said foaming agent being higher than the curing temperature of said plastisol, drawing said encapsulated yarn through a sizing die to bring the encapsulated yarn to a selected thickness, and curing said thread at least to a degree such that said thread can withstand subsequent stresses in forming into a finished fabric, said degree ranging from partial cure to full cure, at a temperature below that at which said foaming agent is activated.
A method of producing a fabric of a flattened encapsulated yarn, comprising the steps of passing a fabric woven of thread of at least partially cured latent foam-encapsulated yarn, a partially cured thread being one which can withstand the stress of weaving the tentering, said thread being essentially circular in cross-section, through a tenter frame which applies tension on both the warp and fill directions while heating said fabric to a temperature high enough to activate the foaming agent in said thread, soften said thread and complete the cure of said thread where only partially cured, whereby said thread simultaneously expands and is flattened and bonded at the points where warp and fill cross.
A ravel-resistant, generally planar fabric comprising a yarn of core filament coated with foamed vinyl resin, said core filament consisting of multi-filament yarn, said vinyl resin applied to said core filament as a viscous liquid, said yarn being arranged in a pattern such as to form yarn junctions, and being generally flattened in the plane of said fabric and bonded at said junctions.
An expansible thread, comprising a multifilament core yarn of a material selected from the group consisting of nylon, rayon, polyester and glass, encapsulated in a plastisol containing a foaming agent, said plastisol applied to said core yarn as a viscous liquid, said plastisol being less than fully cured and cured to the point where it can withstand the stresses of subsequent processing.
A method of forming a flattened fabric of thread of foamed plastisol around multifilament core, comprising the steps of forming a fabric of at least partially cured thread of latent-foam plastisol or filament thread, heating said fabric to activate the foaming agent in said plastisol, to soften said plastisol and to complete the cure of same where only partially cured, and calendering said fabric to flatten same to a selected degree, whereby said thread is welded at junctions.
A method of producing a fabric of a flattened impregnated and encapsulated yarn, the method comprising the steps of:
- weaving a fabric of threads having a multifilament core coated with a foaming agent and a resin which are applied to said core as a viscous liquid;
- heating said woven fabric to a temperature high enough to activate said foaming agent and soften the fabric, thereby simultaneously expanding and flattening said threads and bonding said threads at the points where warp and fill threads cross.
Dependencies are inferred from the claim text.