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Title:
A COMPOSITE FABRIC LAMINATED USING HEAT TREATMENT
Document Type and Number:
WIPO Patent Application WO/2022/010447
Kind Code:
A1
Abstract:
The present invention relates to a multi-layer (composite) upholstery fabric produced by the heat treatment lamination method. What is mentioned here is that it contains a composite structure whose layers are fixed to each other only by the of heat treatment without using any adhesive or flame lamination.

Inventors:
YENİCE AYSUN (TR)
HOCKENBERGER ASLI (TR)
Application Number:
PCT/TR2021/050712
Publication Date:
January 13, 2022
Filing Date:
July 09, 2021
Export Citation:
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Assignee:
KUCUKCALIK TEKSTIL SANAYII VE TICARET A S (TR)
International Classes:
B32B5/26; B32B27/00; B32B37/04; D04H3/14
Foreign References:
US20050257887A12005-11-24
US5187005A1993-02-16
US20030221768A12003-12-04
CN110626023A2019-12-31
GB1389201A1975-04-03
GB1427191A1976-03-10
EP1375132A12004-01-02
KR101271306B12013-06-04
Attorney, Agent or Firm:
METIN, Yesim (TR)
Download PDF:
Claims:
CLAIMS

1. A composite upholstery fabric (100) characterized in that it comprises; fabric (110), sponge (120) and lining (130) laminated to each other using a hot roller, wherein the sponge is located in between the fabric (110) and lining (130).

2. An upholstery fabric (100) according to Claim 1 wherein the fabric (110) comprises melt yarn on the back surface (113) where it integrates with the sponge (120).

3. An upholstery fabric (100) according to Claim 1 wherein the lining (130) comprises a melt yarn on its front surface where it integrates with the sponge (120).

4. An upholstery fabric (100) according to the previous claims characterized in that it also comprises;

- a polyester front surface (111 ) in the top layer of the fabric (110), connecting yarns (112) in the interlayer of the fabric (110), which enable the front and back surfaces (111 , 112) to be connected to each other,

- on the bottom layer of the fabric (110) a bottom surface (113) having polyester melted yarn for adhering to the sponge (120).

Description:
A COMPOSITE FABRIC LAMINATED USING HEAT TREATMENT

Technical Field

The present invention relates to a multi-layer (composite) upholstery fabric produced by the heat treatment lamination method.

In particular, the invention is a composite structure whose layers are fixed to each other only by the of heat treatment without using any adhesive or flame lamination; It includes a melt yarn woven fabric and an upholstery fabric attached to this fabric with connecting yarns, a sponge, and a melt yarn woven fabric that can act as a lining on the bottom layer of the sponge.

Prior Art

It is the process of transforming different surfaces and layers into a single layer by combining them with heat, pressure and adhesives with the lamination technique. Lamination process is applied on all materials with the word laminated. Lamination, which is used in many sectors from textile to printing systems, includes different application techniques. The most used lamination processes are; flame lamination, glue lamination, water-based adhesive lamination, thermal and film lamination and hot melt lamination methods.

In the lamination process of upholstery fabrics in the textile sector; surface fabric, sponge and/or lining are used. In the widely used flame lamination process, the bonding function is performed by the sponge itself. It is fire and water resistant due to its sponge structure.

In the flame lamination process, propane flame is applied on the sponge passing through the machine. The desired amount of melting is created on the sponge surface and the fabric or artificial leather to be laminated at the same time is combined with this surface and bonding is achieved by means of pressurized rollers. If necessary, the second fabric or artificial leather is adhered to the other side of the sponge with the same method. Thus, a laminated fabric with suitable touch, elasticity and fullness is obtained.

However, as a result of the flame lamination process, toxic volatile gases are released. The emission of these gases, which are formed in the working environment, to the environment is also a major problem. These gases coming out of the process also create a bad odor and permeate into the fabric passing through the lamination process and form a chemical layer in the vapor phase inside the vehicle. In the flame lamination process, the burning process requires the burning of the sponge, which causes significant consumption of the sponge material. The decrease in sponge thickness also increases the cost of the process.

In glued lamination, which is another production technique, it is the method of transferring the glue adhesives in the chamber to the product to be laminated by means of a spinning roller. It is generally used in the lamination of fabric, sponge, artificial leather, plush and similar materials. However, in this production technique, there are situations such as damage to the environment and, exposure to chemical effects in the production area.

In thermal and film lamination, which is another production technique, a solid or cut film; It may be carried out on the surface of a heated central drum, wherein the hot-melt adhesive material, provided as a net, is held together as a two-layer compound under the printing layer that is continuously in tension. However, this method is not suitable for heat sensitive fabrics.

As a result of this situation, some of the developed techniques are given below.

In the patent document numbered CN101349013B, ecological type artificial leather or similar leather production method is mentioned. However, there is no solution for bonding the melt yarns to the sponge by melting with the help of heat.

The patent document numbered CN106113650 relates to an upholstery fabric for use in automotive produced by flame lamination method. However, there is no solution for bonding the melt yarns to the sponge by melting with the help of heat.

In the patent document numbered CN106183134, it is about a decorative upholstery fabric for use in the automotive with three layers produced by a kind of adhesive lamination method. However, there is no solution for bonding the melt yarns to the sponge by melting with the help of heat.

As a result, there was a need to produce a multi-layered upholstery fabric using environmentalist methods to overcome the above-mentioned problems in the current art.

Objectives and Brief Description of the Invention

The main purpose of the present invention is; is to obtain a multi-layered upholstery fabric obtained by using environmentally friendly methods, especially by using heat treatment without burning effect. Other aim of the invention is to produce an environmentally friendly product by using less water and reducing the amount of waste water, since it is produced recycled yarns and the coloring process is carried out at the yarn extrusion.

Another aim of the invention is to prevent the release of toxic volatile gases that occur as a result of the flame lamination process to the environment. It is also to prevent the bad odor created by these gases coming out of the process from penetrating into the fabric passing through the lamination process and forming a chemical layer in the vapor phase inside the vehicle.

Another aim of the invention is to stick both the lining and the upholstery fabric on the front side in one step, thus shortening the production process by one step. Thus, it provides cost and time savings.

Another aim of the invention is to produce a standard product with homogeneity and quality. Since this homogeneity in the automotive sector also affects parameters such as comfort and post-use fold marks, the sponge should be of the same thickness and homogeneity. This method also fixes such problems.

Further aim of the invention is to obtain a product that does not harm the nature and the environment and resets the chemical consumption rate by preventing the use of chemicals used for bonding in the lamination method applied with adhesive.

In order to realize the above-mentioned purposes, the invention is a composite upholstery fabric characterized in that it comprises; fabric, sponge and lining laminated to each other using a hot roller, wherein the sponge is located in between the fabric and lining.

In its alternative embodiment, the invention includes melts yarn on the back surface, where the fabric integrates with the sponge.

In another preferred embodiment of the invention, wherein the lining contains melt yarn on its front surface, where the lining integrates with the sponge.

The subject of the invention is an alternative application of a composite fabric laminated using heat treatment comprises,

- a polyester front surface in the top layer of the fabric, connecting yarns in the interlayer of the fabric which enable the front and back surfaces to be connected to each other,

- on the bottom layer of the fabric a bottom surface, having polyester melted yarn for adhering to the sponge, fabric with melt yarn that will act as a lining on the bottom of the sponge.

Brief Description of the Figures

In Figure 1 ; the cross-sectional view of the layers of the upholstery fabric which is the subject of the invention is given.

In Figure 2; the appearance of the upholstery fabric, which is the subject of the invention, at the end of production is given.

Reference Numbers

100. Upholstery fabric

110. Fabric

111. Front surface

112. Connecting yarns

113. Back surface

120. Sponge

130. Lining

200. Press roller

Detailed Description of the Invention

The present invention discloses a three-layer composite upholstery fabric (110) produced by heat treatment of the upholstery fabric (100) subjected to the flame lamination process, using melt yarns that reduce the sponge (120) consumption and ensure the adhesion of the sponge (120) to the fabric.

The subject of the invention is based on the upholstery fabric (100), the fabric (110), that has polyester and melt yarns, and lining (130) becoming an integrated structure with polyester sponge (120) by using press rollers (200) at a certain temperature.

The cross-sectional view of the layers of the upholstery fabric (100) shown in Figure 1 is given. The fabric (110) structure is presented in a three-layer composite form. The front surface (111), which appears as the first level of the layer, is 100% polyester, and it has connecting yarns (112) that connect it with the back surface (113).

In the preferred embodiment of the invention, a three-layer upholstery fabric (100) and a structure that can adhere to the sponge at a certain temperature are formed. This structure has a double layer fabric on the top layer, a single layer fabric on the bottom layer, and a polyester sponge in between. Composite fabric comprises;

- a polyester front surface (111 ) in the top layer of the double-layer fabric (110),

- connecting yarns (112) in the interlayer of the double-layer fabric (110), which enable the front and back surfaces to be connected to each other,

- on the bottom layer of the double-layer fabric (110), a bottom surface (113) having polyester melt yarn for adhering to the sponge (120),

- a single-layer sponge (120) that can be adhered by the heat of the press roller (200) and the effect of the melt yarns, - one-layer lining (130) with melt yarns for the bottom layer of the upholstery fabric (100).

The view of the present upholstery fabric (100) shown in Figure 2, passed through the hot press rollers (200) and attained a composite form is given. Two important elements that reduce the consumption of the sponge (120) in the middle layer of the upholstery fabric (100), which reach the composite form, are the use of polyester fabric (110) which have a bottom layer with melt yarn structure and polyester lining (130) in the production process.

The melt yarns developed by the applicant are protected by the expression of “at least one outer yarn with a lower melting temperature, wrapped on a polyester inner yarn” in the patent number 2015/07441 ; the extrusion of polyester yarns, which are included in the composite upholstery fabric, to be used in curtaining applications are disclosed.




 
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