Patent GB-967350-A (GB)
Title: Production of non-woven polyester fabrics
Inventor: MCINTYRE JAMES ERIC
IPC: D04H3/14
Filed: 1962-05-07
Abstract: A non-woven fabric is made by contacting polyester or copolyester fibres in a substantially non-crystalline state with each other at a temperature above their second order transition temperature and below their crystalline melting point and the bonded fibres thus formed are subsequently caused or permitted to crystallise.  Polyethylene terephthalate is the preferred polyester.  Where copolyesters are used, at least half of the acid component in the copolymeric chaing should consist of a terephthalic acid residue, the other acid component being derived from an aliphatic dicarboxylic acid, e.g. adipic or sebacic acid, or from isophthalic, p-hydroxy-benzoic, p-2-hydroxy-ethoxy benzoic acid or from aliphatic hydroxy acids e.g. hydroxypivalic, hydroxycaproic, hydroxydecanoic, hydroxybutyric or hydroxyvaleric acid.  Polyesters and copolyesters derived from diols other than ethylene glycol, e.g. from 1.4 cyclohexanedimethanol, poly (oxyethylene) glycol, or from mixtures of diols, may be used. Preferably the polyesters or copolyesters used have a second order transition temperature below room temperature, as fibres derived therefrom can be converted into fabrics directly from the spinning head, without the need to maintain them at or raise them to a temperature above room temperature in order to effect bonding and crystallisation.  Before or after bonding the fibres may be heated in a relaxed condition or under controlled tension to allow complete or partial shrinkage.  Pressure and/or tension may be applied during bonding.  Orientation may be imparted to the fibres by drawing after bonding, and the fibres may be heated during or after orientation to set them in a given shape or impart desired shrinkage properties. Other synthetic fibres, or natural fibres, may be dispersed between the polyester fibres if desired. Such fibres become incorporated in the fabric by adhesion to the tacky fibres or are held in position by the bonded fibres. Additional bonding between the dispersed fibres as well as between the bonded fibres may be effected by known methods. In examples: (1) a 50 mole per cent copolymer of polyethylene terephthalate and polyethylene adipate having a second order transition temperature in the amorphous state below room temperature, is melt-spun at 150 DEG C. and the filaments cross-wound on a rectangular block by rotating the block and moving it perpendicularly to its axis of rotation, so that successive layers of parallel filaments lie at right angles.  The filaments adhere to each other at above room temperature and a fabric-like material is obtained.  On standing at room temperature the fibres crystallise and the filaments lose their tackiness.  (2) A similar method is used, filaments being collected on a square board.  (3) Filaments are collected in bobbin in such a way that successive layers overlap at angles ranging from 20-90 degrees on different bobbins, to obtain a tubular fabric, which may be slit to give a flat fabric.  (4) A 70:30 mole per cent copolymer of polyethylene terephthalate and polyethylene sebacate having a second order transition temperature in the amorphous state below room temperatures is melt-spun at 200 DEG C. and collected on bobbins as in (3).  (5) The copolymer of (1) is melt-spun by the method of (3), using an overlap angle of 30 degrees.  (6) An undrawn 50 denier polyethylene terephthalate multifilament yarn is chopped into foot lengths and laid down in lengths parallel to each other, successive layers being at right angles, and the structure pressed between plates at 5 lb. per sq. ft. and at 120 DEG C.