SE502738C2 - Elastomeric satd. nonwoven material - Google Patents

Abstract

Elastomeric satd. nonwoven material comprises (a) fibrous nonwoven web and (b) polymeric material impregnated into the web. A laminate of at least one layer of the above material and at least one other layer is also claimed. Formation of an elastomeric satd. nonwoven material, esp. as above, comprises (1) impregnating a fibrous nonwoven web with a saturant compsn. including a polymeric material distributed throughout the web; (2) densifying to 25-65 lbs/ft.3 and (3) drying or densifying before impregnation. Also claimed is formation of the laminate by bonding at least one layer of material to the elastomeric satd. nonwoven material, and a printing blanket or cushion comprising at least one layer of the above web.

Description

502 738 10 15 20 25 30 35 2 2 having improved internal cohesion or adhesion and surface abrasion resistance, washability / color retention, with unchanged feel or grip; and which may have leather-like properties including suppleness, flexibility and leather-like feel.

A number of impregnated nonwoven webs are known in the art.

Thus, US-A-3,502,763 (Hartmann) discloses nonwoven fibrous fur products having a fabric structure which is characterized in that the fabric is formed of monofilament strands assembled in such a manner as to obtain a fabric thereof having statistically varying filament directions within the strands. wherein the filaments are arranged in a weave-like or knit-like pattern. The filaments are formed of fiber-forming mullets. spinning nozzles, each consisting of a linear row fed into and extruded from a plurality or line of more than, for example, 100 holes, filaments after extrusion through the holes being removed by means of heated gas streams, which exert a pull on and orient the filaments. This patent shows that due to variation in gas flow and polymer flow rate along the hole width, the fabrics have good strength and toughness because mechanical stress is absorbed by filaments having different elongation properties. This patent further teaches that by subsequent impregnation of the fur product with synthetic resins or sizing agents, the properties of the products can be improved. For illustrative purposes, this patent discloses that impregnation with silicone resins results in improved spreadability: and that a significant improvement in washability has been achieved by treatment with curable plastics, such as those containing free methylol groups.

U.S. Pat. No. 4,107,374 (Kusunose, et al.) Discloses a nonwoven fabric which can be used as a base for synthetic leather and which has a relatively high flexural stiffness, the fabric consisting of a plurality of fiber bundles, twisted together. wherein the fiber bundles consist of a plurality of extremely fine filaments or fibers with a denier of 0.005 - and which spontaneously adhere to each other without the use of glue or glue. This patent discloses that the fiber bundles may consist of a regenerated cellulose rayon, cellulose diacetate, cellulose triacetate or a synthetic polymer, for example polyamide, polyacrylonitrile, polyethylene or polypropylene. It further appears from this patent that the described nonwoven fabric can be converted into synthetic leather by impregnating the fabric with an elastic, synthetic polymer, for example polyurethane, synthetic rubber such as NBR and SBR, elastic polyvinyl chloride: elastic or elastic copolymer , acrylic polymers; polyamino acid; two or more monomers for the polymers described above. According to this patent, the obtained leather-like sheet or layer can be divided into two or more pieces of the desired thickness by splitting the sheet or layer with a cutting device along its surface.

US-A-4 656 081 (Ando, et al) discloses a meltblown, nonwoven layer having a smooth and smooth surface, reversible for heat retention and thermal insulation, IEI 'aV which is wherein the layer consists mainly of fine fibers , which are individually distributed substantially in the whole layer and mainly oriented in the longitudinal direction, the layer also comprising yarn-like fiber bundles of fine fibers, which are also oriented in the longitudinal direction of the layers, the yarn-like fiber bundles in number exceeding the fine fibers on one surface of the layer material and the fine fibers in number surpass the yarn-like bundles of fibers on the other surface of the layer material. This patent further discloses that synthetic organic polymers useful for forming the layer include polymers that can be melt spun (melt spray), such as polyolefin, polyester, polyamide, polyurethane, fluorine type, ion type polymers, etc. The said patent further states that it is possible to produce synthetic leather by impregnating a layer structure with an elastic resin and then subjecting it to a polishing process or a coating process. U.S. Patent No. 4,434,205 (Fujii, et al.) Discloses an imitation leather made by impregnating a specific nonwoven substrate with an elastic polymeric material. The substrate may be either (1) a nonwoven fabric consisting of a plurality of stacked and intertwined long fibers forming one of the cross-sectional planes extending between one surface of the nonwoven fabric or a portion thereof, and another surface thereof. nonwoven fabric or a portion thereof, or (2) a nonwoven fabric laminate obtained by laminating a woven or nonwoven fabric on a nonwoven fabric or a compressed form thereof, and, if necessary, compressing the resulting laminate, wherein the latter nonwoven fabric consists of a plurality of stacked and twisted, long fibers forming one of the cross-sectional planes extending between one surface of the latter nonwoven fabric or a portion thereof, and another surface of the latter nonwoven the fabric or part thereof. It is apparent from this patent that the nonwoven fabric can be made from fibers of a thermoplastic, examples of which include polyolefins such as homopolymers of ethylene, propylene, butene-in-, 4-methylpentene-1, or other alpha olefins, copolymers thereof, and mixtures of these polymers, polyamides such as nylon 6, nylon 66, nylon 612, nylon 12, and their mixtures, polyesters such as polyethylene terephthalate, polybutylene terephthalate and polyurethane, in particular thermoplastic polyurethane, ethylene vinyl acetate copolymers, ethylene-methacrylic acid ester copolymers and graft polymers of polyolefins with unsaturated carboxylic acids or their derivatives. This patent further describes that any polymer used in the art of making artificial leather can be used as the impregnating material, with preferred examples of the polymers including elastomers or elastic polymers, for example synthetic rubbers such as polyurethane, NBR and SBR, polyvinyl chloride , polyamides, such as nylon 6, nylon 66 and methoxymethylated polyamides, acrylic polymers or copolymers thereof. 10 15 20 25 30 35 saz 732 While each of U.S. Patents 3,502,763; 4,107,474; 4,656,081; and 4,434,205 disclose impregnated nonwoven webs in which the impregnate is an elastic material, these patents do not disclose that the material formed is an elastic material. Furthermore, these patents do not disclose that the formed materials have improved surface abrasion resistance or other desired properties, which are provided according to the present invention.

U.S. Patent No. 4,812,357 (O'Rell, et al.) Discloses an elastic, compressible printing fabric having dimensional stability and compressibility having an intermediate stabilizing layer of thermoplastic reinforced elastomer having a high modulus of elasticity between a layer of compressible rubber and a external pressure surface. The intermediate layer is made of a thermoplastic, reinforced elastomer composition comprising an elastomer and a thermoplastic polymer. Illustrative elastomers include natural rubbers, fluoroelastomers, SBR, EPDM, butyl rubber, nitrile rubber, neoprenes, and polyurethanes, etc. The thermoplastic reinforced polymer should be in the form of a fiber and may be made of polyolefins, polyvinyl chloride, polyamides, etc. The weight ratio of elastomer to thermoplastic polymer is from about 90:10 to about 10:90 and the thermoplastic polymer has a high tensile strength. The described fabric also comprises a compressible layer, which may be either "foamed" (foam) or "non-foamed", although a foam layer is preferred: and may be made of good synthetic rubber, such as nitrile, polyisoprene, polybutadiene, butyl of any elastomeric material, integrity and elasticity, including natural rubber, rubber, styrene-butadiene copolymers and ethylene-propylene copolymers, polyacrylic polymers, polyurethanes, epichlorohydrins, chlorosulfonated polyethylenes, silicone rubber or fluorosilicone rubber. While US-A-4,812,357 discloses a printing fabric comprising a component layer of thermoplastic reinforced elastomer and a compressible layer, it is still desirable to provide a printing fabric comprising a layer having substantial compressibility and elasticity in Z direction, which can be easily manufactured, together with the component layer itself.G Consequently, it is still desirable to provide a nonwoven elastomeric material and a process for producing such a material, where the material can be provided with leather-like properties including suppleness, flexibility and leather-like feel, and which material exhibits resistance to surface abrasion and washability / color retention without any loss of feel or grip. Furthermore, it is desirable to provide a nonwoven elastomeric material and method for making the same, which has various applications including a component of a printing fabric.

Accordingly, it is an object of the present invention to provide a nonwoven elastomeric material having a nonwoven fibrous web which is abrasion resistant and has good washability, yet which retains the original feel or grip of the material, and a process for production of this material.

It is a further object of the present invention to provide a nonwoven elastomeric material comprising a fibrous web which can be provided with suede-like properties having substantial elasticity and recovery, and which can also give the material a substantial flexibility and " case".

A further object of the invention is to provide a nonwoven elastic material comprising a fibrous web which exhibits compressibility and recovery (elasticity) in the Z-direction.

It is a further object of the invention to provide an elastomeric laminate material comprising a nonwoven elastomeric material containing a nonwoven fibrous web, as mentioned above, and a process for producing such a laminate material. Yet another object of the invention is to provide a nonwoven elastomeric material comprising a nonwoven web of fibers which is useful in various applications, such as for printed matter.

The above object is achieved according to the present invention, which relates to a nonwoven elastomeric material comprising a nonwoven fibrous web, which is impregnated with a polymeric material so that the obtained, impregnated web exhibits elastomeric properties.

It is desirable if the nonwoven web is made of elastic fiber material; it is even more desirable if the web consists of a melt-blown web (made of melt-blown fibers) or a spritz web or a filament web of elastomeric material. Furthermore, the web may be a web containing a mixture of different materials.

A number of elastomeric materials can be used for the fibrous material in the nonwoven fibrous web. Illustrative materials, but not limiting, include polyurethanes, polyether esters, styrene-type block copolymers, EVA (ethylene vinyl acetate) and EVA derivatives. Desirably, the nonwoven fibrous web is impregnated with the polymeric material (the impregnating agent) to form the impregnated, nonwoven elastomeric material. Materials for impregnation may include olefins, acrylics, vinyls, urethanes, vinyl acetates, styrene, butadiene, copolymers of these materials butyl rubber, natural rubber, neoprene, and the like so that the impregnated material formed is an elastomeric material. Thus, the impregnating agent need not necessarily be elastomeric, although it may be so.

The impregnating agent can be introduced into the fibrous web using an aqueous composition (for example, a latex composition).

The composition used for impregnating the fibrous web may desirably comprise a surfactant to accelerate the impregnation of the fibrous web. Furthermore, a fixative (e.g., a compound that gels at higher temperatures) may be included in the impregnation composition to prevent migration of the composition from the web after impregnation thereof.

Various known impregnation methods can be used to obtain the impregnated product. For example, the fibrous web can be immersed in the impregnating composition and then pressed to remove excess (the "dipping and pressing method"); furthermore, the fibrous web can be flowed with the impregnating composition (ie the composition can be directed towards the web through a shower nozzle, using clamping rollers to After impregnating the fibrous web with the impregnating agent, the impregnated web is dried and, if necessary, the plastic or resin contained therein is cured.

In accordance with the present invention, the impregnated, nonwoven elastomeric material has good compressibility / recovery (elasticity) properties in the Z direction (thickness direction). However, these elastic properties in the Z-direction can be improved by a densification or densification of the material. This densification can be carried out by calendering the fiber web, either before or after the impregnation thereof. Preferably, the densification is carried out after impregnation of the web with the composition.

According to the present invention, the impregnated, nonwoven elastomeric material may form part of a laminate. Thus, the laminate may comprise at least two layers (webs) of the impregnated, nonwoven elastomeric material. Furthermore, the laminate may comprise at least two webs, at least one of which is constituted by the impregnated, non-woven elastomeric web, the other or the other webs may, for example, consist of another type of web material (such as an impregnated, elastic paper, woven fabric, or a film such as a polyester film, a low density polyethylene film or a high density polyethylene film). Furthermore, the impregnated, nonwoven elastomeric material of the present invention can be reinforced or reinforced with mesh or woven material, resulting in materials with oblique stretching and recovery.

The laminate of the present invention comprising at least one impregnated, nonwoven elastomeric web can be prepared by conventional methods of bonding two or more webs. For example, a suitable adhesive, either liquid or thermoplastic, can be used to bond adjacent webs to each other. These adhesives are illustrative and non-limiting, and other techniques can also be used to form the laminate, such as heat bonding, adhesive bonding, ultrasonic bonding, and laser bonding.

The impregnated, nonwoven elastomeric material according to pressure bonding, bonding by water jet treatment can be subjected to, for example, polishing or roughening to provide materials with a leather-like feel.

Furthermore, the materials can then be divided into narrow strips for knitting or weaving to obtain unique fabrics.

Applications for these materials may include, but are not limited to, clothing, furniture, footwear, automotive apparel, and leisure fabrics.

Specific areas of use for the impregnated, nonwoven elastomeric material according to the invention appear from the following description. Thus, the material can be used as a flexographic printing plate pad. The material can also be used in providing an offset printing fabric, elastic, by incorporating a layer of the impregnated, nonwoven elastomeric material. Other uses for the material include (1) vibration damping pads; (2) gaskets; (3) permanent underwear labels; (4) adhesive, stretchable, malleable, protective masking for delicate, delicate, oddly shaped objects; (5) car clothing (6) coatings on polished grains for treated fabrics to obtain a harness polishing device; wood, plastic or metal, having intricate contours; and (7) security tape. Accordingly, according to the present invention, there is provided a nonwoven elastomeric material which can be easily produced, which has good abrasion resistance and internal adhesion or coherence and good washability / color retention, and yet retains its original feel; and which can be used to obtain a suede-like material with substantial elasticity / recovery, and with a high degree of flexibility and fall.

In the accompanying drawings, Fig. 1 schematically shows a first embodiment for forming the impregnated, nonwoven elastomeric material according to the invention, Fig. 2 schematically shows a second embodiment for forming the impregnated, nonwoven elastomeric material according to the invention, Fig. 3 schematically shows a third embodiment for forming the impregnated, nonwoven elastomeric material according to the invention, Fig. 4 schematically shows the densification of the impregnated, nonwoven elastomeric web, Fig. 5 schematically shows the formation of two-layer or three-layer laminate according to the present invention, and Fig. 6 shows an impregnated, nonwoven elastomeric material according to the present invention incorporated in a printing plate pad.

While the invention will be described in connection with specific embodiments, it will be appreciated that the intention is not to limit the invention to these embodiments. On the contrary, it is intended to cover all variations, modifications, and equivalent embodiments within the scope of the invention as defined in the appended claims.

Before describing the invention in detail, various terms used herein will be defined.

The term "elastic" or "elastomer" is used herein to denote any material which, when applying a biasing force, is extensible to a stretched, biased length of at least about 125%, i.e. at least 1.25 times its unloaded, non-prestressed length, and which will recover at least about 40% of its elongation or elongation at relief of the tensile force.A hypothetical example which would meet this definition of an elastic material or an elastomeric material would be a 25.4 mm sample of a material which is stretchable to at least 31.75 mm and which, when stretched to 31.75 mm and relieved, will return to a length of not more than 29.2 mm Many elastic materials can be stretched by much more than 25% (ie to much more than 125% of their unloaded length), and for example some elastic materials can be stretched 100% or more, and many of these will return to mainly its original, bred length, for example to within 105% of its original unloaded length when relieving the tensile force.

As used herein, the term "meltblown fibers" refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular nozzle capillaries in the form of molten threads or filaments into a high flow gas stream (e.g., air). The meltblown fibers are then carried by the high velocity gas stream and precipitated on a collection surface to form a web of randomly dispersed, meltblown fibers (referred to herein as a meltblown fiber web). fibers or a meltblown web) Such a process is described, for example, in US-A-3,848,241 (Butine).

As used herein, the term "spruce fibers" or "filament fibers" refers to small diameter fibers formed by the extrusion or extrusion of a molten thermoplastic material into filaments from a plurality of fine, usually circular, capillaries in a die, the diameter being for the extruded filaments is then rapidly reduced, for example, by extraction or other well-known spraying mechanisms.The production of nonwoven spraying or filament webs is illustrated in, for example, U.S. Pat. Nos. 4,340,563 and 3,692,618.

As used herein, the term "elongation" or "percent elongation" refers to a ratio which is calculated by determining the difference between the elongated and unstretched lengths of a material in a particular dimension and by dividing this difference by the unstretched length of the material in the same dimension.

As used herein, the term "Z-direction" refers to the thickness direction of a material layer, i.e., the direction perpendicular to the plane of the length and width dimensions.

As used herein, the term "melt spun nonwoven web" refers to a nonwoven web formed by melt spinning processes. A melt-spun, nonwoven fiber web may be, for example, a web of meltblown fibers or a web of spirit filaments.

As used herein, the term "total absorbed energy" (TEA) refers to the total area (ie, energy) under a curve showing stress versus elongation (load versus elongation). TEA is expressed in (gram force) (cm) / (cm) 2.

As used herein, the term "nonwoven" refers to any web of material formed without the use of any weaving process which provides a structure of individual fibers which interlock in an identifiable manner. Specific examples of nonwoven webs include, without limitation, a meltblown, nonwoven web, a nonwoven filament web, and a carded web. Nonwoven webs typically have an average basis weight of from about 5 to about 300 g / m 2. In particular, nonwoven webs may have an average basis weight of from about 10 to about 100 g / m 2.

As used herein, the term "blend material" means a composite material comprising a mixture of two or more different fibers or a mixture of fibers and particulate materials. Such mixtures can be obtained by supplying fibers and / or particulate materials to the gas stream in which meltblown fibers are moved so that there is an intimate mixture of meltblown fibers and the materials (e.g. wood pulp, staple fibers and particulate materials, such as hydrocolloid (hydrogel) particles, commonly referred to as superabsorbents) prior to accumulation of the meltblown fibers on a collection device to form a continuous web of randomly dispersed, meltblown fibers and the other materials . The formation of such "blends" is described in U.S. Patent No. 4,100,324, the contents of which are incorporated herein by reference in their entirety.

The present invention relates to an impregnated, nonwoven elastomeric material comprising a nonwoven fibrous web (for example, an elastic fibrous web formed of meltblown fibers, or a spunbonded web) impregnated with a polymeric material, the impregnated web formed being elastomeric or consisting of an elastomeric web. The present invention also relates to impregnated, nonwoven elastomeric material. The invention further relates to a laminate comprising said impregnated, nonwoven elastomeric web, and a process for producing this laminate. In addition, the invention relates to various applications of this impregnated, nonwoven elastomeric web comprising at least a portion of a printing fabric.

The impregnated, nonwoven elastomeric material of the present invention exhibits compression capacity in the Z-direction and recovery, durability and washability / color retention (compared to, for example, an elastomeric web of meltblown fibers without impregnation), without loss of feel or grip. Furthermore, the impregnated, nonwoven elastomeric material of the invention can be provided with suede-like properties including flexibility, flexibility, fall and leather-like feel, and can be treated to exhibit stretching with recovery, especially when the impregnated material is subjected to polishing or roughening. Furthermore, the impregnated, nonwoven elastomeric material has extremely good internal adhesion as the fibrous web of the impregnated nonwoven elastomeric and improved abrasive material is formed of meltblown fibers and the fibrous web is formed by use of a plurality of sets of meltblown nozzles (which provide a plurality of layers of meltblown fibers).

As mentioned above, the impregnated, nonwoven elastomeric material of the invention comprises a nonwoven fibrous web.

The nonwoven web is preferably a spunbond web, or a web of meltblown fibers, and most preferably is an elastomeric web of meltblown fibers or a spunbond web. The webs can be prepared in a conventional manner. Typical processes for making nonwoven, meltblown elastomeric webs are described in the aforementioned US-A-4,741,949 and in US-A-4,707,398 (Boggs). Typical mechanical properties of meltblown elastomeric webs, according to the present invention, include, for example, a basis weight of 17-70 g / m 2; the machine direction (MD) of 650-10000, and in the transverse direction a maximum tensile load, expressed in g, i (CD) of 525-8430; a maximum elongation, expressed as a percentage, in the machine direction of 185-550, and in the transverse direction of 255-S50; a load decay, at 200% elongation in the machine direction of 25-30 and in the transverse direction 25-30; a thickness, expressed in mm, of 0.10-0.76: a porosity, expressed in ft3 / ftz / min of 58-921; and a diameter of the meltblown fibers, expressed in μm, of 3.3-35.2, preferably 8.5-22.0. These typical mechanical properties of a meltblown web for use in the invention are given for illustrative purposes only, and are not limiting.

As already mentioned, the elastomeric fibrous web may be a meltblown (nonwoven) web of various elastomeric materials; A specific elastomeric material is Arnitelü EM-400 from (Akzo Plastics, Arnhem, The Netherlands). Other useful elastomeric materials include, for example, a copolyetherester. block copolymers of the general formula AB-A ', where A and A' are each a thermoplastic polymer end block containing a styrene moiety, such as a poly (vinylarene), and where B is an elastomeric polymer middle block, such as a conjugated diene or and lower alkene polymer. Such block copolymers may be, for example, (polystyrene) poly (ethylene-butane) / (polystyrene) block copolymers available from Shell Chemical Company under the trademark KRATRONOG.

Other exemplary elastomeric materials may be polyurethane elastomeric materials, such as those available under the trademark ESTANEO from B.F. Goddrich & Co, polyamide cargo materials, such as those available under the trademark PEBAXO from Rilsan Company, and polyester cargo materials, such as those, are available under the designation Hytrel from E.I. DuPont De Nemours & Company. The formation of elastic nonwoven webs SOIII from certain polyesters is described in, for example, U.S. Patent No. 4,741,949 (Morman et al), the contents of which are incorporated herein by reference in their entirety. The elastomeric material may also be a copolymer of ethylene and at least one vinyl monomer, such as, for example, the vinyl acetate, unsaturated, aliphatic monocarboxylic acids, and esters of the same monocarboxylic acids. The formation of elastic sheets or layers of such elastic copolymers is described, for example, in U.S. Patent No. 4,803,117, which is incorporated herein by reference in its entirety.

Of course, the invention is not limited to the use of meltblown elastomeric webs as the nonwoven fibrous web. Other nonwoven materials, such as filament webs and "blend webs", can also be used if they are capable of achieving the desired compressive strength and recovery in the Z-direction as well as total elasticity.

Various latexes can be used as carriers for impregnating the fibrous web. The impregnating agent need not be of the elastomer type, as long as the impregnated web retains elastomeric properties, as defined above. The various impregnating agents may include an acrylic latex, a nitrile rubber latex, a styrene-butadiene rubber latex, a natural butadiene rubber latex, a high tensile acrylic type latex and a polyurethane latex. Among these various latexes, the softer the polymeric binder (impregnating agent), such as natural butadiene rubber, is, the less the effect on elongation and feel. The inelastic (hard) acrylic latex gave the best improvement in tensile strength, among the latexes mentioned above.

However, all structures having said latexs as impregnating agents achieved better overall properties compared to the unimpregnated fiber web.

The impregnating agents described above are illustrative only of various latexes which can be used to form the impregnated nonwoven elastomeric material of the present invention, and other latexes may also be used which, in the final product, give an elastic material and which can be introduced. in the fiber web without significant damage to the web. The impregnation can be carried out using aqueous latexes. Furthermore, it is desirable that a surfactant be incorporated into the impregnation composition to accelerate impregnation (wetting) of the fibrous web. Such surfactants may include (but are not limited to) "Igepal" 887 (a product of GAF Chemical Corp) and "Triton" X100 (a product of Rohm & Haas Co.).

Furthermore, the impregnating composition preferably also comprises a fixative or a fixing agent to minimize migration of impregnating agent into the fibrous web after impregnation, for example during drying of the impregnated web. In this regard, significant migration of impregnating agents can occur during drying of the heavier impregnated fiber webs. This migration can be minimized using such a fixative. A malignant fixative is "Cartafix" U (manufactured by Sandoz Chemical Co), the fixative may be a material which gels at a higher temperature of 50 ° C. Generally as gels at temperatures obtained during drying of the impregnated web, although this fixative is not limited to such materials.

Various methods for impregnating the nonwoven web will be discussed below. A typical impregnation equipment is of the type marketed by Black-Clawson Co. This equipment consists of a chip-type unrolling roller (from which the nonwoven web is unwound); a steel / rubber roller press nip: transport rollers; edge stretching rollers (transverse direction) arranged on both edges of the web; a retaining roller; a steam-heated drying section; and a take-up roller. The unrolling roller has sensitive tension control means to prevent "deflection" or contraction of the web in the transverse direction of the machine, and may include a driven unrolling aid unit for light elastomeric webs. The press nip consists of a lower steel roller partially lowered into an impregnating agent composition and an upper rubber-coated roller arranged to extrude excess impregnating agent composition. The compression pressure can vary from 2.1 in. 6.3 xp / cmz, range of 3.2-5.3 kp / cmz. A shower nozzle for the impregnating composition is arranged over the web with a preferred one just before entering the press nip while the lower steel roller receives the composition in the trough. This carefully wets both track surfaces with an excess of impregnating agent.

With regard to this typical impregnation equipment, reference is made to Fig. 1. This figure shows a unwinding roller 1, from which, for example, an elastic fiber web 3, which is impregnated, is unwound. A shower nozzle 5 flows the upper surface of the elastomeric web with impregnating agent; furthermore, a lower press roll 7 of chromium steel receives impregnating agent, from a container 9 for supplying the lower surface of the elastomeric web with impregnating agent. The web is pressed between the lower roll 7 and a rubber-coated upper press roll 11 to extrude excess impregnating agent from the web.

The web is then allowed to pass the transport roller 13 and between tension rollers 15 (a pair arranged next to each edge of the web). The web then passes a retaining roll 17 and is dried by means of the preheated drying rollers 19. The dried impregnated web is then moved to a winding roll. 502 738 10 15 20 25 30 35 18 The total solids content of the impregnating agent composition, the compression pressure and the weight of the fibrous web (for example the meltblown elastomeric web) are all factors which affect the uptake of impregnating agents. The total solids content of the impregnating composition varies from 10% by weight to 60% by weight depending on the desired uptake of dry impregnating agent. The uptake, calculated on dry weight, varies from 10 parts by weight to 120 parts by weight of impregnating agent per 100 parts by weight of web of fibrous material. A preferred uptake, based on dry weight, varies from 20 parts by weight to 70 parts by weight of impregnating agent per 100 parts by weight of fibrous web (PPHP) and total solids contents of impregnating agent within a range of 20-40% in the impregnating agent composition are used. The uptake of impregnating agents, calculated on wet weight, can vary from 50 parts by weight to 300 parts by weight per 100 parts by weight of fiber web.

Immediately after the press nip, the web may pass a curved stretching roller to stretch the web outward, and two sets of pressure rollers located at both edges of the web to further stretch the web outward. Both devices remove wrinkle tendencies and prevent "deflection" of the fibrous web. The retaining roller located just before the drying section regulates the tension in the drying rollers. The steam-heated drying rollers are regulated to a temperature in the range 93-112 ° C, although this range is only illustrative and not limiting. At relatively high temperatures (eg temperatures exceeding 121 ° C), the impregnated fibrous web tends to warp, twist and deteriorate the physical properties of the impregnated, nonwoven elastomeric material.

When the web has passed the drying section, the web is wound on a drum roll system, which can either cool or heat the dry web depending on the required hardening of the impregnating agent. 10 15 20 25 30 35 502 738 19 An alternative embodiment for impregnating the fiber web is based on the "dipping and pressing" method.

This method uses containers containing the impregnating composition, which container is arranged between the unrolling roller and the press nip. The entire web is lowered into the composition and the excess is pressed out at the press rollers. This "immersion and pressing" method is shown schematically in Fig. 2. In this Fig. The same reference numerals are found as in Fig. 1. The embodiment according to Fig. 2 differs from the embodiment according to Fig. 1 in that the embodiment according to Fig. 2 includes a container 21 , through which the fiber web passes, and in that this embodiment does not comprise the shower nozzle 3 according to Fig. 1.

The embodiment according to Fig. 2 comprises the press nip formed by the rubber-coated upper press roll 11 and the lower press roll 7 of chrome steel for forcing out excess impregnating agent from the web.

A treatment device comprising two steel rollers with adjustable nip can also be used for the impregnation by applying an impregnating agent or a coating on both sides of the nonwoven fibrous web (elastomeric web). Reference is made to Fig. 3. In accordance with the embodiment shown therein, the web 3 is allowed to pass between the upper and lower supply nozzles 23 and 25, respectively, to apply impregnating agent or coating to both surfaces of the fibrous web and to flow the nip 25 between the upper clamp the chrome-steel roller 27 and the lower chrome-plated roller 29. The upper and lower clamping rollers are adjustable to obtain an adjustable pinch. The nip regulates how much impregnating agent or coating remains in or on the web. The weight of the web, total solids content and set nip are all factors that affect the desired uptake of impregnating agent or coating. The treated web is then passed through upper and lower gas-fired air blast furnaces 31 and 33, respectively; these furnaces supply heated air to the top and bottom of the web to remove moisture and to keep the web "floating". J2 10 15 20 25 30 35 7258 20 "Two cooling rollers on the exit of the furnaces provide cooling of the dry, heated web and / again, the treated web can either be wound up in a cooled or hot state depending on the curing mechanism which takes place in the impregnating agent or coating compositions.

In each of the methods described above, the machine speed may vary from 15 to 183 m / min depending on the weight of the fibrous web, the desired degree of uptake (dry weight) and the speed of removal of water in the drying sections. The basis weight of the fibrous webs can vary from 6.75 to 185 g / m2, with a preferred range being 34-170 g / m2.

The fiber web can be bonded or unbonded before impregnation. For example, when the fibrous web is an elastomeric web made of meltblown fibers, the web may be unbound or heat bonded prior to impregnation.

Various latex compositions can be used for impregnation of the fibrous web. Some of these have been discussed above.

As mentioned above, the latexes may comprise as the polymer an elastomeric polymer, such as polyurethane, natural rubber, butyl rubber, NBR, SBR, acrylics including elastic acrylics, etc.

A typical elastomeric polymer impregnation composition may comprise the following, which is given by way of example and non-limiting (stated values for the compositions in the wet and dry state are parts by weight; the rest of the wet composition is water): Table 1 Ingredient § Dry yett Urethane latex UB -40-S12 37 100 270.3 XAMA-7 100 1 1 Ammonium oxalate 5 0.05 1.0 "Triton" X-100 33 1.9 5.8 Color pigments KR-7071 25 10 40.0 Ammonium hydroxide 14 0.5 3.57 TOTAL 35.2% 113.45 321.9 10 15 20 25 30 35 502 738 21 Suppliers of the above ingredients: Hardener KM-10-1415 Virginia Chemicals Uretan Latex UE-40-512 Permuthane, Inc.

Color pigment KR-7071 Member of the ICI group "Triton" X-100 Rohm & Haas Co.

As mentioned above, the cured, impregnated, nonwoven elastomeric material has improved properties including improved compressibility / recovery (elasticity) in the Z direction, compared to, for example, the unimpregnated fiber web (e.g., an unimpregnated, nonwoven web of meltblown fibers). However, to further improve the compressibility / recovery in the Z-direction, the nonwoven material can be subjected to a densification treatment (densification or density increase). This can be done either on a calender comprising steel rollers or a supercalender where rollers of steel and fibers are arranged alternately. These calendars can comprise 7 or 9 rollers and these are usually pressurized. Calendering can be performed before or after impregnation of the fibrous web, but an increase in density is preferably carried out after impregnation.

The density obtained by the densification process varies from 0.4 to 1.04 g / cm 3, with a preferred range being 0.56-0.88 g / cm 3.

Reference is made to Fig. 4, which schematically shows a calender for increasing the density of the nonwoven material of the present invention. Accordingly, the nonwoven material (impregnated, nonwoven elastomeric material) 37 is unrolled from the unrolling roll 35 and is allowed to pass between the rollers 39 (or in the supercalender of Fig. 4 is allowed to pass between alternating calender steel rollers 39 and calender fiber rollers 41). After calendering, the elastomeric web is wound with increased density on the roller 43.

As mentioned above, the impregnated, nonwoven elastomeric material may be used as such or may form part of a laminate of this material and other webs, such as another impregnated, nonwoven elastomeric fabric, impregnated elastically 502 738 10 15 20 25 30 35 22, etc. These composite webs increase the stability of the impregnated, nonwoven elastomeric material in both the machine direction and the transverse direction without significantly deviating from the compressibility / recovery (elasticity) in the Z direction. The choice of substrate to be used for the stabilizing web depends on the end use.

Adhesives to be used for laminating composite webs can be any suitable adhesive, liquid or thermoplastic, which provides proper bonding (bonding) of the two webs. Such adhesives must, of course, be those which retain any necessary elasticity for the laminate. Conventional adhesives are known in the art. In addition, the webs can be laminated by, for example, heat bonding (heat bonding) as is known in the art.

Fig. 5 schematically illustrates the formation of a two- or three-layer laminate according to the present invention.

In general, lamination involves unwinding web material from one of the rollers, applying an adhesive to this web, positioning the second web adjacent the first web surface having the adhesive thereon, allowing the adjacent webs to pass between upper and lower bonding or bonding rollers, and then winding. the laminate obtained.

Specifically, as shown in Fig. 5, the impregnated, nonwoven elastomeric material 45 is unrolled from the roll 44 and passed adjacent the wet lens applicator 49, the adhesive being applied by the applicator 49 from a container 47 containing adhesive. After application of the adhesive, the web may pass a dosing device 51 (for example a knife blade or a wire-wound rod) to provide the desired amount of adhesive. Thereafter, a second layer (e.g., film, a nonwoven fabric web, a woven web, etc.) 53 is unrolled from a supply roll 55 and disposed adjacent to the nonwoven material 45 at the side thereof on which the adhesive is applied. Thereafter, the webs 45 and 53 are allowed to pass between upper and lower rollers (each either heated, to a temperature of, for example, 225 ° C or not heated) located at room temperature or cooled, where the webs 45 and 53 are joined together to form the laminate. The laminate 65 is then wound on a roller 67.

The upper and lower rollers 63 and 57 are pressure rollers, which can operate at different pressures, and are heated or cooled, or are at room temperature.

A laminate consisting of three layers or a composition of more than three layers also falls within the scope of the inventive idea. In the case of a three-layer laminate, glue is applied to the upper surface of the web 45, as is known in the art, and a third web 59 is unrolled from the supply roll 61 so that the web will be adjacent to the upper surface of the web 45 before passing between the upper and lower rollers 63 and 57. Upon passage through rollers 63 and 57, the three layers are laminated.

Above, both the nonwoven material and the laminate of the present invention have been described together with various techniques for forming this nonwoven material and laminate. Various applications of this material and this laminate will be discussed below. The impregnated, nonwoven elastic material of the present invention, due to its physical properties, such as elasticity, abrasion resistance, toughness, elasticity in the Z-direction, etc. has applications in the form of a number of new products.

A first application of the present invention is as a flexographic printing plate pad. A typical flexographic printing plate pad utilizing at least one layer of impregnated, nonwoven elastomeric material in accordance with the present invention is shown in Fig. 6. In Fig. 6, reference numeral 69 denotes a polyester film or a solvent-resistant coating layer (e.g., having a thickness of 0.05 mm); layer 71 is each a laminating adhesive, each such layer having a total thickness of 0.05 mm; layer 75 is of elastic, (for example, densified to a density of 0.83 g / cm 3, and with a thickness of 0.53 mm); and layer 77 is an impregnated paper 502 738 10 15 20 25 30 35 pressure sensitive adhesive or glue intended to attach the cushion to a printing press cylinder, said layer 77 having, for example, a thickness of 0.043 mm. The impregnated, nonwoven elastomeric material of the invention is used for the layer 73; for illustrative purposes, this material, which is used as indicated in Fig. 6, is densified to an approximate density of 0.69 / cm 3, and has a thickness of 0.34 mm. The total thickness of the cushion in this case amounts to 1.02 mm, which is typical of flexographic newsprint presses.

In general, there are a large number of elastic, flexographic printing plate cushion materials on the market. These products are quite expensive and most have a short lifespan. Pillow materials available on the market are available in a number of thicknesses ranging from 3.8 mm to about 1.5 mm.

Due to this wide range of cushion thicknesses required for different types of flexographic printing presses, laminates are necessary to build the caliber in an inexpensive manner, to stabilize the nonwoven web and to provide solvent resistance on one surface with either a coating or a layer. If an impregnated, nonwoven elastic material according to the invention is used as a component or constituent of an elastic, flexographic printing plate cushion, it is possible to give materials which are already on the market equivalent properties with respect to compressibility / recovery (elasticity) in the Z-direction . Furthermore, various advantages are obtained with the nonwoven material according to the invention, including improved mechanical properties when using the nonwoven material according to the invention as part of a flexographic printing plate pad.

Another use for the nonwoven material of the present invention is for permanent underwear labels. Due to its softness, flexibility, washability and comfort against the skin as well as the fact that the material according to the invention can be printed, it has clear advantages compared to currently used underwear labels, which typically consist of imitations. 738 25 impregnated, nonwoven polyethylene terephthalate materials, which tend to be stiff and hard against the skin.

A further application of the nonwoven material according to the invention is as a protective coating. Since the nonwoven material according to the invention is stretchable and malleable, a layer of this material provided with an adhesive or glue can be adapted to a surface of delicate, sensitive, oddly shaped objects to provide protection for these, especially when the surface of such objects need protection with respect to handling, dirt and scratches.

Another product application is like a car upholstery or a car fabric, malleable to fit internal parts of the car, especially when ceiling-mounted instrument panels are used. which need to be stretchable and The nonwoven material according to the invention can also be incorporated in an offset printing cloth. Furthermore, coated or coated abrasive grains can be applied which are elastic. the nonwoven material for obtaining an abrasive or polishing device for objects of wood, plastic or metal, which have intricate contours (ie where abrasive cloth or abrasives applied to paper are not practical). The most important properties for this use are the elasticity, toughness and formability of layers or sheets of the nonwoven material of the present invention.

The nonwoven material according to the invention can be used in particular for electronic cleaning rooms to prevent fingerprints for the manufacture of safety tape from contaminating sensitive components.

Only certain uses of the nonwoven material according to the invention have been described above and these are only Various other applications can be readily appreciated by those skilled in the art. Certain factors, illustrative and non-limiting. which could limit the use of the nonwoven material according to the invention is that the material can be easily stretched (has a low modulus, which could cause distortion of the web); is heat sensitive to some extent (for example, in some cases at temperatures exceeding 120 ° C); and could be unsuitable from an elongation point of view.

Below are specific examples of nonwoven materials of the present invention and methods for their preparation. Of course, these examples are illustrative only and not limiting.

Example 1 The following materials were used to make latex type impregnation compositions: LBÜBXEI '- Pigment - Miscellaneous - RHOPLEXQ TR407 (Rohm & Haas) (acrylic emulsion hard rubber) HYCARO 1572X64 (BF Goodrich Chemical Group) (Nitrile V Goodrich Chemical Group) (high tensile acrylic load) PERMUTHANEO UE40-512 (Permuthane, Inc.) (aliphatic polyurethane) DALAMAR YELLOW, YW958-P (Heubach Inc.) MONOLITE BLUE, BXE-HD (ICI Americas Inc.) UNISPERSE RED, FBN-P1 (Ceiba-Geigy Corp.) PERMUTHANE, KR7071 (Permuthane Inc.) CYMELO 303, (American Cyanamid) (crosslinking agent; harder) BOSTEXO 378 (Akron Dispersions Inc.) (sulfur dispersion) BOSTEXQ 4978 (Akron Dispersions Inc.) ( zinc dibutyl zimate ((ZDBZ) (accelerator and crosslinking agent) IGEPALO 887 (Gaf Chemical Corp.) (wetting agent) TRITONG X100 (Rohm & Haas Co.) (wetting agent) BOSTEXO 422 (Akron Dispersions Inc.) (zinc oxide dispersion) PERMUTHANEG 14 Inc.) (crosslinking agent) CARTAFIXQ U (Sand oz Chemical Co.) (fixative) 10 15 20 25 30 35 502 5738 27 Impregnation compositions: 1. Latex type - acrylic, Tg = + 30 ° C. Dry RHOPLEXO TR407 (45.5) 100 219.8 TRITONO X100 (33) 1.9 5.8 CYMBLO 303 (100) 2.1 2.1 Ammonium nitrate (10) 1.35 13.6 Ammonium hydroxide (14) 2.2 15.7 DALAMAR YELLOW, YW958-p (45) 10 22.2 Water 15.3 TOTAL (40) 117.6 294.5 Curing: 100 ° C / 3 h 2. Latex type - nitrile rubber, Tg = - 30 ° C å Dry passed HYCARO 1572X64 (47.2) 100 211.9 BOSTEXO 422 (60) 5 8.3 BOSTEXÛ 378 (60) 2 4 BOSTEXO 497B (50) 1 2 IGEPALO 887 (20) 1.35 6, 8 Ammonium hydroxide (14) 0.45 3.2 MONOLITE BLUE, BXE-HD (48) 10 20.8 Water 42.8 TOTAL (40) 120.8 299.8 Curing: 107 ° C / 10 min 502 738 28 3 Latex type - elasto-acrylic, Tg - -43 ° C g 'tubular Lai; HYCARO V43 (53) 100 188.7 TRITONO X100 (33) 1.9 5.8 5 Ammonium hydroxide (14) 2.2 15.7 BOSTEXO 422 (60) 5 8.3 UNISPERSE RED, FBN-P1 (42) 10 23.8 Water 55.5 10 TOTAL (40) 119.1 297.8 Curing: l00 ° C / 3 h 15 4. Latex type - polyether urethane Dry PERMUTHANEO UE40-512 (37) 100 270.3 PERMUTHANEO KM10-1415 (80) l 1,3 Anuonium oxalar (s) o, 05 1 1, o 20 TRITON0 X100 (33) 1,9 5,8 PERMUTHANEO KR7071 (25) 10 40,0 Ammonium hydroxide (14) 0,5 3,6 TOTAL (35) 113.5 322 25 Curing: 100 ° C / 1 h 30 35 10 15 20 25 30 35 50.2 "738 29 5. Latex type - elasto-acrylic, Tg = -43 ° C (thermosetting composition) å Dry passed HYCARO V43 (53) 100 188.7 TRITON0 X100 (33) 1.9 5.8 Ammonium hydroxide (14) 2.2 15.7 BOSTEXO.422 (60) 5 8.3 UNISPERSE RED, FBN-P1 (42) 10 23.8 CARTAFIXO U (25) 10 40 Water 40.5 TOTAL (40) 129.1 322.8 Curing: 100 ° C / 3 h The following procedure was used for the impregnation of meltblown "Arnitel" Akzo Corp. Arnhem, Holland), respectively 187 g / m2, basis weight of 30 g / m2.

The impregnating compositions were added with extra ammonia and surfactant to improve the mechanical stability of the latex and to promote wetting of the web.

The impregnating composition was poured into a container and the web was lowered therein before excess was forced out by passing the web through a nip between rubber rollers (Durometer: Shore A hardness = 70) at a pressure of 1.78 kg / cm 2. Each impregnating composition was diluted to 15 ° C. % solids content (a polyether ester from with a basis weight of 31 g / m2 and of meltblown polypropylene with one for a second (lower) application. The samples were impregnated sequentially and stacked before drying.

Drying was performed by applying each layer or sheet to a "Teflon" 0-coated, steam-heated jar (107 ° C) followed by penetration of impregnating agent. While the handling of the frequent rotation to minimize heavier material was easy, the handling of the light samples was not so easy as only intermittent contact with the dryer could be achieved without creasing or wrinkling, since the drying time was short. Air drying was also carried out by hanging the layers placed on a wooden stand, pulled from a smoke hatch. When necessary, the samples were cured by stacking, wrapping and sealing in "Mylar" 0 and heating at the prescribed temperature for a suitable period of time.

The layers formed were then tested for various properties including abrasion resistance (Martindale, using rubber pads / 12 KPa (0.2 kg / cm 2) and quark children.

The abrasion test showed that the fibrous webs without any impregnating agent could not withstand the abrasion test. Of the impregnated webs, the nonwoven material impregnated with the high tensile elastomer showed the greatest abrasion, while the other impregnated materials remained virtually undamaged. Furthermore, this test showed that migration of the latex to the surfaces offered somewhat better abrasion resistance. The low weight materials (ie using the relatively low basis weight fiber webs) were more sensitive to abrasion than the heavier webs.

Regarding the abrasion resistance acquired by latex impregnation, these polymers can be ranked in descending order: "Permuthane" 0 UE 40-512, "Rhoplex" 0 TR 407, "Hycar" 0 l572X64 and "Hycar" 0 V43.

The layers were washed in warm water and rinsed for one and five cycles. The samples were assessed for integrity and color (Hunter Color System). The results from washing of latex-treated, meltblown elastomers corresponded to the ranking obtained in the abrasion test.

Example 2 The following specimens were subjected to compression / recovery (elasticity) testing in the Z direction: 1. Specimen A - 5 OSY meltblown elastomeric EMB base fabric, not impregnated or bonded. Layers that were loosely folded up. 10 15 20 25 30 35 502 738 31 2. Sample B - 5 OSY EMB impregnated to 50 receptacles (ie one receptacle or addition of 50 dry parts by weight of impregnating agent per 100 parts by weight of fibrous web material) with polyurethane elastomer. Two test pieces, which were loosely folded. Sample C - 5 OSY EMB impregnated into 20 receptacles with polyurethane elastomer. Two test pieces, which were loosely folded. Sample D - elastic paper, impregnated (in the laboratory) to 60 recordings with acrylic latex, densified (in the laboratory). Two test pieces, which were loosely folded. Sample E - a specimen "D" arranged loosely on the upper part of a specimen "B". The upper specimen was subjected to direct pressure from the test instrument support plate. Test piece F - a test piece "B" the upper part of the test piece "D". Sample G - 5 OSY EMB impregnated with nitrile elastomer (MER) for 50 recordings. Two test pieces, which were loosely folded. Sample H - 5 OSY BMB impregnated with acrylic elastomer for 50 recordings. Two test pieces, which were loosely folded. Sample I - a specimen "D" the upper part of a specimen "H". Sample J - a test piece "H" the upper part of a test piece "D". Sample K - cohesive offset printing fabric (in the printing industry referred to as "stickyback") manufactured by David M. Co, made of Kimlon type elastic paper.

Rubber pressure surface facing the test support plate. Sample L - "stickyback" cloth made by W.R. Grace Co under the brand Polyfibron. Rubber pressure surface facing test support plate.

The following test procedure was used to test compressibility / recovery. A test specimen was cut to a suitable size of 19-50.8 mm. A caliber measuring device of the type Ames was pre-loaded with a weight of 340.2 g. Then the foot was raised with a diameter of 6.35 mm on this measuring device with a lever and the specimen was placed between the foot and the support. Then lower the foot slowly and carefully against the test piece. After 10 s, a caliber measurement was performed and this value is called “original caliber.” Thereafter, a 2.27 kg weight of 340.2 g weight was carefully placed and held in place for 30 s. Then a measurement was made and 2.27 This test value is called the "compressed measurement value". The specimen was then allowed to recover for 10 s after removal of the 2.27 kg weight but with 340.2 g of the weight still in place.Then a caliber determination was performed, whereby this is called "recovery value".

The results of the compression / recovery test for each of the specimens are shown in Table 2 below. As shown in this Table 2, each of the impregnated materials achieved better recovery than the unimpregnated base fabric.

Table 2 Compressibility / Recovery Test Original Z Compressed Non-Retractable Z Non-Reconciled Sample Caliber Compressed Originally Retrieved from Capture (inches x 10'3) (inches x 10'3) Caliber (inches x 10'3) jump caliber B 37.8 16.9 44.70 6.9 18.25 B 43.5 16.4 37.70 4.6 10.60 C 43.1 18.2 42.23 6, 0 13.90 D 23.3 2.2 9.44 0.5 2.15 E 38.1 9.8 25.70 2.9 7.61 F 36.1 10.1 28.00 3.1 8.59 G 43.2 17.1 39.60 4.8 11.10 H 39.6 15.8 39.90 6.4 16.20 I 34.1 9.3 27.30 3.3 9.68 J 32 .9 8.6 6.10 3.4 10.33 K 35.5 1.7 4.80 0.4 1.13 L 36.6 2.7 7.40 0.7 1.91 10 15 20 25 Example 3 The following sample materials were tested for compressibility / recovery using the elasticity in the Z direction. Sample AA impregnated into 50 receptacles with polyurethane elastomer. only one layer tested. Reported results are averages from two trials. Sample AB - 5 OSY EMB impregnated to 20 sockets with polyurethane elastomer. Only one layer tested.

Reported results are averages from two trials. - 5 OSY meltblown elastomeric web (EMB) One- 3. Test piece AC - elastic paper, laboratory impregnated to 60 recordings with acrylic latex, laboratory identified. Two layers (laminated) with a barrier-coated layer as a laboratory sample. The reported results are mean from two trials. Sample Tyoke AD-5 OSY EMB, polyurethane impregnated to 50 recordings and densified. Sample AE - same as "AD" but lower density. Sample AF-5 OSY EMB impregnated with hard acrylate for 50 recordings, densified to high density. Sample AG - as "AF" but lower density. Sample AH - 5 OSY SMB impregnated with nitrile rubber (MBR) for 50 recordings and densified. 9. Sample AI - as "AH" with lower density. Sample AJ - 5 OSY EMB impregnated with nitrile rubber (MER) for 50 recordings, and densified to high density. ll. Sample AK - as "AJ" 12. Sample AL - urethane foam manufactured by Norwood Ind, and marketed by Kimberly-Clark Corp as Kimflex, Reported results but low density. 762 mp flexographic printing cloth cushion. is mean from two trials. 13. Sample AM urethane foam (source unknown) 101.6 pm flexographic printing pad. Reported results are mean values from two trials. 502 738 10 15 20 25 30 35 34 14. Sample piece AN - continuous offset printing cloth, referred to in the printing industry as "stickyback", manufactured by David M. Co using elastic paper marketed under the Kimlon fl brand as a frame. Rubber pressure surface facing test support plate. Reported results are mean from two trials. _ 15. Sample AO - "stickyback" printing cloth made by W.R. Grace Co under the name “polyfibron.” Rubber pressure surface facing the foot. Reported results are averages from two experiments.

The following procedure was used to determine the compressibility and recovery (expressed in%) in the Z direction of the test pieces described above using a Federal Dial Comparator type device equipped with a 1.42 cm diameter foot and a support plate with a diameter of 0.64 cm; this process is an application of ASTM D 1147-5lT and 53T, and is intended for short-term compressibility and recovery at room temperature. To begin with, test chips were punched with a 3.81 cm punch and the caliber and weight (g) of each chip were determined. Thereafter, main loads were placed one at a time on the test plate support plate and deviations were determined; this reading is added to the main load weight after the experiment as a corrected value.

The sample is then placed on the support plate and a preload is applied; after 15 s a caliber reading (P) is made. This value is taken at the end of 15 s. Thereafter, the main load is applied in a slowly uniform manner so that the full load is reached within 10 s. The main load is maintained for 60 s (total elapsed time 85 s) and a caliber reading is made; immediately thereafter, the main load is removed. The sample is retained on the support plate to recover for another 60 s (total elapsed time 145 s) and a final caliber reading (R) is performed. These steps are applied to each sample.

The percentage compressibility is (P-M) x 100 / P. The recovery in percent is (R-M) x 100 / P-M. Percent not recovered is (P-R) x 100 / P. The results regarding compressibility, recovery and non-recovery, all expressed as a percentage, are shown in Table 3.

As is clear from Table 3, the nonwoven materials of the invention show good recovery after compression. Furthermore, the densified or densified nonwoven material of the invention has further improved compressibility / recovery properties.

For example, the impregnated, nonwoven elastomeric material of the present invention can be compressed in the Z-direction about 18% at a load of about 34.1 kg / cm 2 and can recover to about 70% of its original Z-direction dimension. At this load, an exemplary material could be compressed about 20% and then recover to about 93.5% of its original dimension. At a load of about 10.8 kg / cm 2, the material of the present invention has a Z-direction compressibility of about 5% and a recovery of about 80%. As an example, a material could be compressed approximately 5.4% at a load of approximately 10.8 kg / cm 2 and then recover to approximately 98% of its original dimension. at a load of about 66.4 kg / cm 2, the material of the present invention can be compressed about 33% and recovered in about 64% of its original dimension. An exemplary material could be compressed approximately 33% at a load of approximately 66.4 kg / cm 2 and then exhibit a recovery rate of approximately 87% of its original dimension. 502 738 36 ° m- -mm _U- @ ° _m> _ @. ° __, -_ @ _ _-, ~ - @ ~ _ M Q fi -_M ._ ~ _ m @ _ ~ _ ° _ @ ~ ma. ~ _ @ @___ @ __ @ @ ~ _ ~ @ _m ~ _ @ _ ~ °° _ @ _ _ @ ~ ~ _ @ ~ @ _ @ _ @ _ ~ @ = <@ _ @ ~ M @ _ ~ ~ _ ° @. @ _ ~ @___ ~ m_m @ ~ _ ~ _ _-O ~ _ ~ _ @ ° __ @ _ ~ @ @@ _ ° m_, ~ ~ @ _ ~ ° ° _n_ m fi w Q. "_m. ° ~ _ ° ° -_ ° ~ _ ° @@ _ ° ° ._ ~ _ .mä @ _- @ _._ m_.m ° <° _ ~ _ °° __ __ ~ @ @@ _ ~ m_- ° ~ _. _Ss_ ~ _ -0 0.0 ~ @ _ ° m_ ~ @ ~ ° __ @ _ @ _ @__ ~ ~ m_ ~ _ ma. »__ _ ~ _ ° ~ _ @@ ~ __ ° __m @ ° _ ° @ ° _ ~ _ _m_ ~ _ ~ _ _ _ _ _ ~ H ~ _ ~ @ m fl ~ _- @m_m @__> ~ @ _ ~ ~ _ @ _ m ° _m -_ ~ _ __, ___ ~ @ m_ ~ °. »~ ___ ~ æ_ ° _ am .. -_ ~ _ mø- m__ ~ n ~ _ ~ @ _m @ -_H @ _ @ ~ mv." ~ ° _ ~ fi _m_ @ _ ~ m __m ~ @_. Mm <@ .m ~. ~ _N ... ß ~ __ ~ ~ ___ >> _ W @ ° _ ~ _ __ »m _ @ _ ~ n_ ~ m__ @ @@ _ ~ ° _ @ ~ @ fi_ m ° @ _m_ mc. _ _ __ ~ _ »w__ 0.5» ~ @__ @ _m ~ ° __m ___ @ _ _m_ “___ @ m_ _ am = <@___ °° _ ~. ._ @ ø _ @ _ ~ ° _- _m_m __m ~ _., ~ _ ~ ~ @__ m_ ~, -_ ~ m_ ° ñ “___ ° _m ~ mm- _ _ _ 0.» @@ _ ° ._ @@ - ° _ ~ ß_ ~ ~, ._ @__ ~ _m_ Q fi m ° @ ~ ~ @__ 04 ° _ ° M ~ m_m ° _ ° ~ ° ~ _m @ _ ° @ @ ~ __ ~ m _ @ _ _. ° @ _- mn .. ~ _ @ ~ = ~ _m __ ~ m ~ m_ ° ~ _ø_ mwv _ _ _ ° _ @ _, ~ _ @ ° _- ° ~ _n @ _m ~ mm_ @ M_ @ H _m_ Q - M m ~ Q ~ @ m <mm @ ~ ~ @ mm m__ ~ _ @ _ m ° _ ~ mm @___ __ ° ~ -va ° __ ~ _ »_ ~ _ @ ~ ~ @ m @ ~ U ° _ m._ ° _ ~ __ ~ m0. _ _ _ Q ”_. ~. ~ ~ _ @@ - M _ _" @ v_ @ @. ° ~ _m_ c - w _ ~ _ _ ~ << -.__- M ° -. = ~ - @ ~ _- M = _- =. M ° _ ~ == ~ ~. ° _ ~ == ~ Q ° _- = ~ fi m fl - ~ \ @ == @ ~. ° _ ~. = ~ ~ _ °° ~ _ \ @ == @> °. @ .. @ ==. @ «~ = --Wg .. @ == H@w.= -Um = - @ fi_ ~ x ~ x ° ~ .. - @ ~ _ ~ ¥ @ = ~ = ~ @ ~ _ - @ = ~ = Mmmm * axw> u ~ => ~ .-. W = --uw @ = ° ~> ~ - .. w = ..- <. @ m == ~ @ w ~ =. = ~ .. ~ w. @@ ==. @@. =. @@ ~ @ -. ~ Qw_ ~ = .. @ ~ «@ ~ ° _» .. @ ~ wn> ~ - ° ~ _ ~. = @ == ~ ww M __ @@@ ~ Table 3 (continued) 2 together-! not re- Not re- retrieved by retrieved X re- printed by retrieved by party- Caliber Tappi Origin- True- original- Ater- Base weight Density loading caliber printed caliber retrieved original- sample Pound / 1300 FZ tunx10'3 lbs / ft3 tuuxl0'3 tu | xl0'3 caliber original- caliber tu | x10'3 tu | x10 ' 3 tu | xl0'3 PS1 lïÉI-I _ _ Iïlïll fi f fl fV, àw-nê c fi nwæ _ _ O-ilfißß ïC-Gä 21,5 54,5 rwæwa âw-va _ _ _ c-Oï fi 'GFI% G \ -Q -u fi ê B fi c fififi FlrIlF-l 154 485 944 42.8 14.05 65.2 37 lfïíï 'lfi fl åßâ 0-19-1 lfïfüí 331% _ _ _ ïv-llš Lfïíßê _ _ _ íšb fl f) ïíï v-ccwcw l \ $ '_ _ _ Swif fl läffiï âw-ovf) w-oßn fl ä 14.7 61.0 fifl- ï _ _ ïäï I-II-Iw fi l flflfi í Éß fi lf) _ _ _ lïïf fifl) & f fi aids 'ííï G fiflfl f fi í flfi lfï un-šo: l *} \ 9 Gñált- ïlïí' héïï _ _ _ ïI-iiï I fl lv-Ü 38,3 27,9 7 lfiß fi ï ___ ï fi i fl ä Éí fi Öi _ _ _ låffilï lläwíï ïu-lï 311 arbø ~ w fl cfnnß _ _ _ Ow fl- nb wav-o Cšl * \ l5 _ _ _ íïäß fl áufzuä Iäïï Ö \ I * _ _ I _ O _ I * _ \ u-lo-dv-l Iïíï Jêäí ÜÜÜ 'ffiffàf fi 154 485 944 35,1 38,1 144,6 fi lí fifi _ _ _ O-llï fi) ê fi nn (fi ïwl _ _ _ ÉÉF-I Ö fi ißlï _ 3513 flfi íl * rñêr fl íl * rñêr _ I fl ll fi í 'Qäíí ïv-O ua (V fi ílï fäïï' I-ÅCÜIÉ 35,7 502 738 IQCÉJ _ _ _ (Öíí ïá flfl 'w-líí' _ _ c-ilšlä Zív-í ídf fi v-O 3353 fv fi ß _ _ c-O fl åí ÉZQC Iïlïfš Q-4CQ âïu fi æ-øßa «_ï-¿_š 223.8 502 738 10 15 20 25 30 35 38 Example 4 Some materials in this example were made from nonwoven elastomeric webs of meltblown polyester fibers (ärnitelß EM-400 from Akzo Plastics, Arnhem, The Netherlands) with base weights of 31.5 g / m2 and 187 g / m2 respectively. Other materials of this example were made from a nonwoven web of meltblown polypropylene fibers having a basis weight of about 30.2 g / m 2. The nonwoven webs were impregnated using the impregnating agents and methods of Example 1. The materials were tested for porosity, strength, elongation, total absorbed energy and trapezoidal tear strength.

The stretching properties of the nonwoven elastomeric webs were determined in both the machine direction (MD) and the cross machine direction (CD). The strength, elongation, total absorbed energy and trapezoidal tear strength were determined in accordance with Method 5100 of Federal Test Method Standard No. 191A using a Constant Rate strain tester, Instron Model 1122 Universal Testin Instrument.

The Frazier porosity was determined using a Frazier air permeability tester available from Frazier Precision Instruments Company. The porosity according to Frazier was determined in accordance with Federal Test Method 5450, Standard No. 191A except that the sample size was 20.3 x 20.3 cm instead of 17.8 x 17.8 cm.

The basis weight of the nonwoven web was determined in accordance with Federal Test Method 5041, Standard No. 19A. The thickness (ie the thickness) of the nonwoven web was determined by an Ames Model 3223 thickness tester available from B.C. Ames Company of Waltham, Massachusetts, USA. The thickness tester was equipped with a 12.7 x 12.7 cm foot.

The thickness of a stack of 10 10.2 x 10.2 cm specimens was determined at a load of 182 g.

The thickness of a single specimen was calculated by dividing the determined thickness by the number of specimens. 50 15 20 25 30 35 502 '738 39 The results of the test for porosity, strength, elongation, total absorbed energy and trapezoidal tear strength are shown in Table 4. As shown in Table 4, the nonwovens of the present invention have good elongation and strength. Furthermore, the impregnated, nonwoven elastomeric materials have maintained their desirable ability to "breathe" as shown by the results of the Frazier porosity test.

Accordingly, the present invention provides a nonwoven elastomeric material having good compressibility and recovery in the Z direction as well as good elasticity and ability to "other". For example, the materials of the invention may be stretched approximately 30% in the machine direction and Some materials of the present invention may be stretched more than 150% in both the machine direction and the cross machine direction. Furthermore, the materials have desirable abrasion resistance and washability without loss of feel. skin-like properties about 40% in the cross-machine direction.

The products can be provided with suede - including flexibility, flexibility and draping while tea and recovery. they exhibit substantial elasticity 502738 40 MMMMMMMMMMMM MMMMM MMMMMMM mmmmmmmmmmmmmmmm MMMMMMMMM MMMMM MMM MMM mmmmmmmmmmmmmmmmmm MMMMMMMMM MMMMM .mm M MMMMMMMMM M mmmmmm MMMMMMMM MM MMMM MMM> MMM M M M .MMM mmmm mmmm mmmm MMM MMM M_MM M_MM M. MM.M MMM MM. MMM MMMMMMM MM M MM M MMMM MMMM MMM MMM M_MM M.MM MM MM.M MMM M.. MMM MMMMMMM MM.M MM.M MM MM MM MM MM_M MM_M MM M..M M.M. .M M M_MM MMMMMMMMMM MM_M MMMM MMM MM. MMM MMM .M.M MM_M MMM M..M M_M. MM M M_MM MMMMMMM MM M MM M MMM .M. MM. M.M MM_M MM.M MMM M..M M_MM M. M M_MM MMMMMMM MM.M MM.M MMMM MMMM MMM MMM. M_M M_MM MM MM.M MMM MM M MMM MMMMMMM MM .. MM.M MMMM MMM. MM. MM. M.MM M_MM MM MM.M MMM MM M MMM MMMMMMM MM.M MM.M MM. MMM MM. .M. MM.M MM_M MMM MM.M ._MM MM M M_MM MMMMMMM MM_M MM.M MMM M .. MM. M.M MM_M MM.M .MM M._M M.M. MM M M_MM MMMMMMM MMUM MM.M MMMM MM.M M .. MM. M.M M_MM MM MM.M MMM MM M MMM MMMMMMM MM M MM.M MMM. MMMM MM. .M. M_MM ... M MM MM.M .MM .M M MMM MMMMMMM MMNM MMUM MMM MMM. MMM MMM .M.M MM.M MMM M..M M_MM MM M M_MM MMMMMMM .M M MM M .M. MM. MMM MMM MM.M MM_M MMM M._M M.M. M. M M_MM MMMMMMM MMUM M.UM MMMM MMMM M .. MM M_MM M.MM .. MM.M MMM MM M MMM MMMMMMM MM M MM M MMMM MMMM MMM MMM MMM M_MM M_MM MM .M_M MMM MM M MMM MMMMMMM MMM s. .. MM MM MM MM MZ M2 MM Mš M_MM. so M_MM MMMOEMMM MM ~ M MM_M MMM MMM .M. MMM MM_M MM.M MMM MM_M M_MM. MMMMM MM.M MMMMMMM MM M MM M MMMM MMMM MM. MM. M_M MM.MM MM MM.M MMM. MMMMM MMM MMMMMMM MM MM MM MM MM MM MM MM MM MMM. Mmmm mmmm MMM MMMMMMM .MMM Mmmmmmmmmm MMMMMMMMMMM _-M MMMMM M_MM MMMMM mmmmmm MMMMMMM MMMMMMMMM mmmmmm MMMMM MMMMMMMMM MMM MMMMM MMMM .MMMMMMM MMMMM MM Mmmmmmmmmm -MMMMM MMMMM MMMMMMM .mmmm .MMM -MMMM -MMMMMM .MMM. MMMMMM

Claims (38)

10 15 20 25 30 35 502l7ss 41 PATENT CLAIMS An impregnated, nonwoven elastomeric material comprising: a nonwoven web of meltblown fibers; and a polymeric material introduced into the nonwoven fibrous web by impregnation, characterized in that the impregnated nonwoven elastomeric material can be compressed in the Z direction at least about 18% at a load of 34.1 kg / cm 2 and recover to at least about 70% of its original Z-direction dimension. Material according to claim 1, characterized in that the nonwoven web of meltblown fibers comprises elastic microfibers. Material according to claim 1, the elastomeric web is made from the basis of the nonwoven an elastomeric material selected from the group consisting of elastic polyesters, elastic polyurethanes, elastic polyamides, elastic copolymers of ethylene and at least one vinyl monomer, and elastic AB-A 'block copolymers, where A and A' are the same or different thermoplastic polymers, and where B is an elastomeric polymer block. Material according to claim 1, in that the polymeric material, which has been introduced into the nonwoven fibrous web by impregnation, consists of a polymeric elastomeric material. Material according to claim 4, characterized in that the polymeric elastomeric material comprises polyurethanes, acrylics, vinyls, nitrile rubbers, butadiene rubbers, styrene-butadiene rubbers, natural rubbers, acetates or copolymers thereof. Material according to claim 5, in that the impregnated, nonwoven elastomeric material is designed to be stretchable at least about 75% in at least one direction. 502 738 10 15 20 25 30 35 42 7. A material according to claim 4, characterized in that the material can be compressed in the Z-direction at least about 18% at a load of about 34.1 kg / cm 2 and recover to at least about 70% of its original Z-direction dimension. Material according to claim 4, characterized in that a nonwoven fibrous web is densified or densified to a density of from about 0.4 to about 1.04 g / cm 3. Laminate of at least one layer of impregnated elastomeric material according to claim 1 and at least one other layer. 10. A laminate according to claim 9, characterized in that the second layer is a layer of impregnated, nonwoven elastomeric material. 11. in that the second layer comprises sparse, woven fiber laminates according to claim 9, characterized by materials, impregnated elastic papers, nonwoven fibrous materials or film. Laminate according to claim 11, characterized in that the film is made of a polyester or a polyolefin. 13. A laminate according to claim 9, in that the impregnated elastomeric material is joined to the known second layer by means of glue or adhesive. A method of making an impregnated nonwoven web comprising the steps of: impregnating a nonwoven web of meltblown elastomeric fibers with an impregnating composition comprising a polymeric material so that the polymeric material is distributed in the nonwoven web, densifying the impregnated nonwoven web into a nonwoven web. from about 0.4 to about 1.04 g / cm 3; and drying the densified or densified impregnated nonwoven web, characterized in that the impregnated nonwoven elastomeric material can be compressed in the Z-direction at least about 18% at a load of 34.1 kg / cm 2 and recover to at least about 70% of its original Z-direction dimension. 10 15 20 25 30 35 502 738 43 A method according to claim 14, in that the nonwoven web is densified before it is impregnated with the impregnating composition. 16. A method according to claim 14, characterized in that the composition consists of a latex composition. A method according to claim 14, wherein the composition comprises a crosslinking agent. A method according to claim 17, in that the polymeric composition is cured. 19. A method according to claim 18, characterized in that the curing and drying steps are carried out in a known manner - n a t n a t together. Process for producing a laminate of at least one layer of impregnated, nonwoven elastomeric material and of at least one other layer, characterized by at least one layer of material being bonded to the layer of nonwoven, impregnated elastomeric material. _ 21. A method according to claim 20, characterized in that the impregnated, nonwoven elastomeric material is joined to the second layer by means of heat, adhesive, pressure, ultrasound, on a hydraulic scale or by means of a laser. A printing fabric comprising, as a component thereof, at least one layer of an impregnated, nonwoven elastomeric material comprising a nonwoven web of meltblown elastomeric fibers, which is impregnated with a polymeric material, characterized in that the material can be compressed in the Z direction at least approximately 18% at a load of approximately 34.1 kg / cm2 and recover to at least approximately 70% of its original Z-direction dimension. A printing fabric according to claim 22, comprising at least one layer of an impregnated, nonwoven elastomeric material and at least one layer comprising an adhesive component for adhering the fabric to a printing press cylinder. 502 738 44 24. A printing fabric according to claim 22, characterized in that the polymeric material which is impregnated in the nonwoven elastomeric fibrous web consists of an elastomeric polymeric material. 5 Printing fabric according to claim 24, characterized in that the elastomeric material comprises polyurethanes, acrylics, vinyls, nitrile rubber, butadiene rubber, styrene-butadiene rubber, natural rubber, acetates or copolymers thereof. A printing fabric according to claim 22, characterized in that the nonwoven web of meltblown elastomeric fibers comprises microfibers. Printing fabric according to claim 22, characterized in that the nonwoven elastomeric web is made of an elastomeric material comprising elastic polyesters, elastic polyurethanes, elastic polyamides, elastic copolymers of ethylene and at least one vinyl monomer, and elastic AB-A ' block segments, where A and A 'are the same or different thermoplastic polymers, and where B is an elastomeric polymer block. A pressure pad comprising at least one layer of an impregnated nonwoven elastomeric material, said impregnated nonwoven elastomeric material comprising a nonwoven web of meltblown elastomeric fibers impregnated with a polymeric material, characterized in that the material can compressed in the Z-direction at least about 18% at a load of about 34.1 kg / cm 2 and recover to at least about 70% of its original Z-direction dimension. A printing pad according to claim 28, comprising at least one layer of an impregnated, nonwoven elastomeric material and at least one layer comprising an adhesive component for attaching the pad to a printing press cylinder. 30. A pressure pad according to claim 28, characterized in that the polymeric material impregnated in the nonwoven elastomeric fibrous web is a polymeric elastomeric material. 10 15 20 25 30 35 50.2 738 45 A pressure pad according to claim 30, wherein the elastomeric material comprises polyurethanes, characterized in - acrylics, vinyls, nitrile rubber, butadiene rubber, styrene-butadiene rubber, natural rubber, acetates or copolymers thereof. A pressure pad according to claim 28, in that the nonwoven web of meltblown elastomeric fibers may comprise microfibers. A pressure pad according to claim 28, in that the nonwoven elastomeric web is made of a characterized elastomeric material comprising elastic polyesters, elastic elastic copolymers and elastic AB-A'- are the same or different polyurethanes, elastic polyamides, of ethylene and at least one vinyl monomer, block copolymers, where A and A 'are thermoplastic polymers, and where B is an elastomeric polymer block. Material according to claim 1, characterized in that the nonwoven web of meltblown elastomeric fibers comprises a mixture of meltblown fibers and at least one other type of material selected from the group consisting of wood pulp, staple fibers and particulate materials. An impregnated nonwoven elastomeric material comprising: a nonwoven web of molten fibrous material; and a polymeric material introduced by impregnation in that the impregnated nonwoven material can be compressed in the Z direction at least about 18% at a load of 34.1 the nonwoven web, characterized kg / cm 2 and recovering at least about 70% of its original Z-direction dimension. Material according to claim 35, characterized in that the nonwoven web of melt-sprayed fibrous material is selected from the group consisting of spirit webs and webs containing a mixture of materials. Pressure pad comprising an impregnated, nonwoven elastomeric material according to claim 35. A printing fabric comprising, as a component thereof, at least one layer of an impregnated, nonwoven elastomeric material according to claim 35.