DE1054416B - Process for the production of deformable objects from non-woven fiber structures - Google Patents

Description

Process for the manufacture of deformable articles from nonwoven Fibrous structures It has long been known that deformable objects, such as dinnerware, Drinkware, vases and also wall coverings and coverings, to be manufactured in such a way that natural or man-made materials such as wood, metal, ceramics, synthetic resin pressed panels and the like, shaped accordingly and decorated if necessary. It is also known to apply patterns to such carrier substances by means of paper or paper pulps or embed in the surface layers to be decorated.

In the manufacture of everyday objects such as z. B. dishes, the procedure is recently such that synthetic resins in powder form be filled into a mold, a paper layer, which may be patterned or decorated, placed on top and the whole thing by pressing, mostly through Hot pressing, is transferred into the desired object.

All of these manufacturing processes are associated with considerable disadvantages. The objects produced in this way are not sufficiently resistant to mechanical ones Actions. If papers are also used, these are used when the pressing process is carried out especially when it comes to the manufacture of objects with curved surfaces often torn or due to the lack of deformability and resilience the paper achieved such unsightly decorative effects that the objects in question are not for sale.

All of the difficulties identified above are in accordance with the present invention thereby avoided; that optionally pre-consolidated fiber structures made of fully synthetic or regenerated fibers or fiber blends of fully synthetic and / or regenerated Fibers and / or cotton or bast fibers on the surface of plastic carrier substances, preferably made of synthetic resin, applied and by means of pressure and heat in the carrier be pressed in.

With this method, the nonwovens can be used without accepting any damage or disturbances are combined with the carrier substances. Here, if necessary Impregnations are still taking place, either at the same time or beforehand or afterwards can be carried out. Due to the stretchability and elastic deformability of the fiber structures they are especially suitable for the production of decorated Objects, especially those with strongly curved surfaces, are well suited. For this purpose, the decorative fleeces can be made by known measures, such as printing, Paint, etc., with patterns, pictures or the like. Be provided.

Fully synthetic fibers, e.g. B. those made of polyamides, polyesters, polyvinyl compounds, also regenerated fibers, z. B. those made of cellulose acetate and the like., Or fiber blends into consideration that except for fully synthetic fibers and / or regenerated fibers or fiber fractions other types of fibers, e.g. B. cellulosic fibers, such as cotton, or cellulosic Fibers such as bast fibers.

It is advantageous to use nonwovens that have a pre-consolidation and surface smoothing. You can z. B. the fleece by application small amounts of adhesive on the surface and subsequent drying and / or subjecting pressing processes to surface hardening and smoothing, wherein the contact points of the fibers on the surface layers are maintained the spaces between the fibers are glued together. This can the nonwovens are stabilized in such a way that they can withstand processing operations such as soaking, Printing, embedding, can be subjected to trouble-free. The pre-consolidation can also be done by gluing with the help of thermoplastic fibers.

The nonwovens can be completely or partially made of thermoplastic Fibers are made and by heat treatment, e.g. B. by guiding the fleece pre-consolidated by heated steel rollers. Through measures such as recruitment the nip, application of certain temperatures, etc., one can give the nonwovens a Give it a coarse to mirror-like texture. The pre-consolidation from fiber nonwovens consisting of or containing thermoplastic fibers also with the help of solvents or swelling agents through which the fibers superficially swollen and with Kren connected to neighboring fibers will succeed.

The pre-consolidated fibrous sheet-like structures can be used directly, e.g. B. by Printing with patterns or pictures, decorated or initially with a Solution, dispersion or emulsion can be impregnated with artificial resin. The impregnation can :. B. by dipping in appropriately concentrated solutions, dispersions or Emulsions of the artificial narcotic, subsequent squeezing to the desired degree of absorption and drying. When carrying out the drying process, it is advisable to be precise Adherence to the drying temperature and drying time in order to harden too far to prevent the thermosetting synthetic resins. It should also be ensured that at Carrying out the drying process resulted in a smooth surface of the fiber structure remain.

The application of the decorations to the fiber structure can be done according to the usual Methods, e.g. B. by printing, coloring, painting, metallizing, docking, etc., take place. The decorative effect can also be achieved by the fiber fleece itself will, :. B. by embedding a coarse-meshed fleece made of oigmented or colored fibers in a different colored background.

The fiber structures can be on one or both sides of the carrier substances be applied. The fiber structures can also be coated on one or both sides will.

The production of the desired objects can be done, for. B. with the help of a two-part heatable press take place, for. B. such that in .the cavity of the Die synthetic resin powder, e.g. B. melamine resin powder, is filled on the Surface of the filling a suitably cut with a pattern, e.g. B. by Imprint, provided, more or less thick fiber structure with the printed side is placed downwards, the press is closed and the synthetic resin is applied by pressure and heating is cured, wherein the fiber structure carrying the decoration is so is fused with the melamine resin that a unitary object is formed. When carrying out this process, several layers of fiber structures, which may be composed of different types, on the surface of the Synthetic resin powder filling are applied.

According to one embodiment of the invention, the fiber fleece is before Placing in the press by pretreatment, e.g. B. preheating, in an easily deformable State transferred. The fiber fleece can also be used before the pattern is applied, z. B. be subjected to a pre-consolidation by printing and optionally with synthetic resin, e.g. B. melamine resin, are impregnated. The impregnation can be done with With the help of solutions, dispersions or emulsions of the synthetic resin.

According to a further embodiment of the invention, there is the basic mass of the object to be produced and decorated from loaded with synthetic resin or coated nonwovens. You can z. B. proceed in such a way that impregnated with synthetic resin Nonwovens are laid one on top of the other in several layers and on the surface a decorative fleece is placed on the multi-layer structure formed in this way, whereupon the Whole by hot pressing in one operation into the desired decorated object, z. B. a plate is transferred. For this purpose thick, loose, non-consolidated nonwovens with synthetic resin, e.g. B. melamine resin, such impregnated so that they have a synthetic resin content of about 60 to 700 / o. Such, z. B. circular cut fiber structures are in the die of a z. B. plate-like mold inserted in the required amount, the decorative fleece is placed on the top layer and by applying heat and pressure the one provided with the decoration Object, e.g. B. a plate made. On objects manufactured in this way the fibers of the fleece used for the construction can no longer be seen. The pattern or image is embedded in the surface layer.

EXAMPLES 1. Two-stage process with molding compound Production of the decorative fleece A random fiber fleece of about 56 g / m2 was made from 1.5 of the Perlon fibers (not matted) 25 mm and 1.8 the acetate fibers (degree of acetylation about 3) 20 mm in the mixing ratio 25: 75 made by stacking eight layers of a thin pile. The thickness of the aggregate thus produced was 7 mm. The fleece was between two heated steel rollers at a roller spacing of 0.1 mm and a temperature of 211 ° C and hardened thermoplastically in the process. The final product has a Thickness of about 0.2 mm. The product so prepared was with a solution of 60 Parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts Water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution of triethanolamine hydrochloride treated. The product was squeezed between two rubber rollers on one Resin uptake of 65 0 / o (dry content) brought. The so soaked fleece was at 90 ° C dried on a heated roller to a content of volatile components from 5 0/0.

Colored images were printed onto this fleece by means of screen printing.

Manufacture of a decorated plate In the die one at 160 ° C preheated plate shape was a-cellulose-filled melamine resin molding compound of about 40 to 60% cellulose content filled in granular form. The amount was measured in such a way that that there was a small amount of excess. The shape was now made using a patrix closed and brought to a pressure of 380 kg / cm2 at a temperature of 160 ° C. After 20 seconds the air was vented and after 1 minute the mold was opened again. The plate was now preformed, but the melamine resin had not yet condensed. The decorative fleece cut in a circle was then placed on the preform with the decorated side down. The mold was closed again and for Condensed for 2½ minutes under the aforementioned conditions. The finished plate could be removed from the mold after this time. 2. One-step process with molding compound Production of the decorative fleece A random fiber fleece of 75 g / m2 was made from 1.5 the Per'lon fibers (not matted) 25 mm and 1.8 the acetate fibers (degree of acetylation about 3) 20 mm in a mixing ratio of 50:50 produced by stacking of about ten layers of a thin card, pile. The thickness of the aggregate so produced was 10 mm. The fleece was between two heated steel rollers at a roller spacing from 0.1 mm and a temperature of 211 ° C sent through and there solidified thermoplastically. The final product had a thickness of 0.2 mm.

Colored images were screen-printed onto the fleece produced in this way imprinted.

After printing, the solidified non-woven fabric was coated with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution treated by triethanolamine hydrochloride. The so soaked fleece was at 90 ° C dried on a heated roller to a content of volatile components from 50 / o. Manufacture of a decorated plate In the die at 160 ° C preheated plate shape was a-cellulose-filled melamine resin molding compound of about 40 to 60% cellulose content filled in powder form. The powder became uniform distributed in the cavity of the die. A circular cut was made on the powder, Decorative fleece produced as described above is applied. The shape was now closed by means of a male mold and at a temperature of 160 ° C to a pressure of 380 kg / cm2. After 20 seconds it was vented and then condensed out for 3½ minutes. After this time, the finished plate with the decorative pattern could be removed will. 3. One-step process with carrier fleece Production of the decorative fleece one Random fiber fleece of about 50 g / m2, consisting of 1.5 perlon fibers (not matted) 40 mm and 3 the acetate fibers (degree of acetylation about 3) 40 mm, was in the mixing ratio 50:50 made by stacking eight layers of a thin pile. the The thickness of the aggregate thus produced was 7 mm. The fleece was between two heated steel rollers at a roller spacing of 0.1 mm and a temperature of 213 ° C and solidified thermoplastic in the process. The end product had a thickness of about 0.2 mm. The product so prepared was with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts Water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution of triethanolamine hydrochloride treated: By squeezing between two rubber rollers, the product was on one Resin absorption of 650 / o (dry content) brought. Production of the carrier fleece A loose fiber fleece of 250 g / m2, consisting of perlon fiber waste 3 to 7 den and Reclaimed cotton, white, was produced in a 50:50 mixing ratio by stacking it on top of one another of twenty-five layers of a thin pile. The nonwoven fabric was mixed with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution treated by triethanolamine hydrochloride. The final product had a resin content of 600 / o (dry weight).

Production of the plate In the die of a preheated to 160 ° C Plate-shaped pieces of the carrier fleece were punched out in a sufficient quantity inserted to make a plate of the desired weight. As top one A round punched-out decorative fleece was placed on the 2nd layer. The shape was now closed by means of a male mold and at a temperature of 160 ° C on one print of 380kg / cm2. It was vented twice after 20 and 30 seconds, respectively. To The finished, decorated plate could be removed after a pressing time of 2½ minutes. 4, one-step process with pure fleece decoration making decoration fleece A fiber fleece of 100 g / m2 weight was made from 400 / o nylon 6 denier, 400 / o perlon 5 den and 300 / o perlon waste 3 to 7 den produced by stacking ten layers of a thin pile. The thickness of the aggregate thus produced was 10 mm. The fleece was between two heated steel rollers at a roller spacing 0.1 mm and a temperature of 216 ° C sent through and thermoplastically solidified. The final product was about 0.2 mm thick. The product thus made was with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution treated by triethanolamine hydrochloride. By squeezing between two rubber rollers the product was brought to a resin absorption of 600 / o (dry content). That so soaked fleece was dried at 90 ° C on a heated roller to a volatile matter content of 5%.

Granular, black molding compound made of phenol-formaldehyde resin filled, the amount of resin so was measured that a small excess was squeezed out when the mold was closed. A circular decorative fleece prepared as described above was placed on the resin powder hung up. The mold was then closed by means of a male mold and at one temperature brought from 160 ° C to a pressure of 380 kg / cm2. After 20 seconds it was vented. After a pressing time of 2½ minutes, the finished, decorated plate could be removed will. 5. One-step process with carrier fleece and non-impregnated decorative fleece production of the decorative fleece A random fiber fleece of 50 g / m2, consisting of 1.5 perlon fibers (not matted) 40 mm and 3 the acetate fibers (degree of acetylation about 3) 40 mm, was prepared in a mixing ratio of 50:50 by stacking eight Layers of a thin pile. The thickness of the aggregate thus produced was 7 mm. The fleece was between two heated steel rollers with a roller spacing of 0.1 mm and a temperature of 213 ° C and thermoplastic solidified. A decoration was applied to the fleece produced in this way by means of screen printing imprinted. The final product was about 0.2 mm thick.

Manufacture of the carrier fleece A loose fiber fleece of 150 g / m2, Consisting of 3 to 7 denier perlon fiber waste and white shredded cotton, was mixed in the ratio 50:50 made. The nonwoven fabric was with a solution of 60 parts of a water-soluble Precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts Ethyl alcohol and 2 parts of a 50% aqueous solution of triethanolamine hydrochloride. The end product had a resin content of 60% (dry weight).

Production of the plate In the die of a preheated to 160 ° C Plate-shaped pieces of the carrier fleece were punched out in a sufficient quantity inserted to make a plate of the desired weight. As top one A round punched-out decorative fleece was placed on the 2nd layer. The shape was now closed by means of a male mold and at a temperature of 160 ° C on one print of 380 kg / cm2. It was vented twice after 20 and 30 seconds, respectively. To The finished, decorated plate could be removed after a pressing time of 2½ minutes. 6 One-step process with carrier fleece for the production of a cup. Manufacture of the decorative fleece A random fiber fleece of 75 9 / m2 made of 1.5, the Perlon fibers (not matted) 25 mm and 1.8 the acetate fibers (degree of acetylation about 3) 20 mm was in the mixing ratio 50:50 produced by stacking about ten layers of a thin carded pile. The thickness of the aggregate produced in this way was about 10 mm. The fleece was between two heated steel rollers with a roller spacing of 0.1 mm and a temperature of 211 ° C sent through and solidified thermoplastically in the process. The end product had a thickness of about 0.2 mm.

Colored decorations were painted on the fleece produced in this way.

After painting, the solidified non-woven fabric was coated with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution treated by triethanolamine hydrochloride. By squeezing between two rubber rollers the product was brought to a resin uptake of 650 / o (dry content)). Manufacturing of the carrier fleece A loose fiber fleece of around 250 g / m2, consisting of perlon fiber waste 3 to 7 denier and white shredded cotton was made in a mixing ratio of 50:50 by tiling on top of one another made of twenty-five layers of a thin carded pile. The nonwoven fabric was with a solution of 60 parts of a water-soluble precondensate of melamine-formaldehyde resin, 32 parts of water, 8 parts of ethyl alcohol and 2 parts of a 50% aqueous solution treated by triethanolamine hydrochloride. The final product had a resin content of about 60% (dry matter). Manufacture of the cup Sufficient layers of the carrier fleece, to fill in the mold when pressing, and a layer of the painted decorative fleece were punched out in a semicircle. The pieces were folded into a bag, with the decorative fleece was on the outside of the bag. Put one in the die at 160 ° C preheated cup shape (without handle) this bag-shaped structure was inserted, and the mold was closed by means of the male mold and at a temperature of 160 ° C brought to a pressure of 380 kg / cm2. It was re-vented twice 20 or 30 seconds. After a pressing time of 3 minutes, the finished, decorated Be removed from the cup. 7. One-step process with polystyrene-soaked fleece production of the decorative fleece A fiber fleece with a weight of 100 g / m2 was made from 800 / o Trevira SK 3 denier, 60 mm yellow, and 200 / o perlon waste 3 to 7 denier by placing them on top of each other made of ten layers of a thin pile. The thickness of the aggregate produced in this way was 10 mm. The fleece was between two heated steel rollers at a roller spacing 0.1 mm and a temperature of 214 ° C sent through and thermoplastically solidified. The final product was approximately 0.2 mm thick.

Production of the carrier fleece A loose fiber fleece of 300 g / m2, consisting of 500 / o perlon fiber waste 3 to 7 denier and 500 / o white recycled cotton, was made by stacking tables. made of about thirty layers of thin pile. The fleece was made with a dispersion of 150 / o weight percent polystyrene in trichlorethylene soaked. After the trichlorethylene had evaporated, the fleece had a resin uptake of about 600 / o. Production of a plate In the die of a heated to 140 ° C In the shape of a plate, punched-out pieces of the carrier fleece were inserted in sufficient Number to give a small excess when pressing. A round cut out yellow decorative fleece was placed on top. The mold was now closed by means of a patrix and here brought to a pressure of 380 kg / cm2 for about 5 minutes. It was cooled down and only then opened the mold, whereupon the finished plate could be removed.

Claims (5)

CLAIMS: 1. Method of making deformable articles made of non-woven fiber structures, characterized in that, if necessary, pre-consolidated Fiber structures made from fully synthetic or regenerated fibers or from fiber blends of fully synthetic and / or regenerated fibers and / or Baumwoa11 or bast fibers applied to the surface of plastic carrier substances, preferably made of synthetic resin and pressed into the carrier by means of pressure and heat. 2. The method according to claim 1, characterized in that the fiber structures on both surfaces .the carrier substances be applied. 3. The method according to claim 1, characterized in that the Fiber structures are coated on both sides with the carrier substances. 4. The method according to claim 1, characterized in that the fiber structures and plastic carrier substances are stacked several times. 5. The method according to claim 1 to 4, characterized in that the fiber structures are patterned before the pressing process, z. B. printed, colored, metallized or flocked.