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    • 专利摘要:
    process for the manufacture of a non-woven cloth, paste, and cloth. a process for manufacturing a non-woven fabric having distributed elements having a physical dimension on a surface, comprises screen printing on damp fabric in a desired manner using a paste that expands under heating due to an inflating agent contained therein.
    公开号:BR112013009052B1
    申请号:R112013009052
    申请日:2011-10-11
    公开日:2019-12-17
    发明作者:Van Mil Jan；Broshi Ron
    申请人:N R Spuntech Ind Ltd；
    IPC主号:
    专利说明:

    ONLINE PROCESS FOR THE MANUFACTURE OF A NON-WOVEN CLOTH, THIXOTROPIC PASTE, AND, NON-WOVEN CLOTH
    FIELD OF THE INVENTION [001] The invention relates to nonwovens. More particularly, the invention relates to the formation of solid elements in the fabric that provide specific physical properties and characteristics to the non-woven material. In particular, the invention provides the ability to control the physical properties of these solid elements as needed.
    KNOWLEDGE OF THE INVENTION [002] Nonwovens are very common in a variety of uses, ranging from cosmetic fabrics to industrial applications. For cleaning purposes, nonwovens are used in all applications, from delicate cosmetic wipes to robust industrial cleaning materials. Such nonwovens can be manufactured in different ways, and one of the industrially efficient processes employed for this purpose is known in the art as "braided". Braiding, or hydroentangling, is a technology that uses water jets to cause the entanglement of fibers and thus the formation of tissue. This is unique among non-woven technologies. The main consequence of the hydroentanglement technique is the fact that the fabric at the end of its creation stage is wet and will require a drying stage.
    [003] To improve the cleaning operation to be carried out, be it delicate cosmetic cleaning or strong industrial cleaning, it is desirable to add solid physical elements to the fabric surface, which will improve the desired cleaning operation. These solid elements can be of an abrasive nature, with varying degrees of abrasion: for the purpose of domestic cleaning, with a lower level of abrasiveness, and for industrial cleaning purposes, with a higher level of abrasiveness, while in both cases, the nature abrasive tissue is derived both from solid elements
    Petition 870190113726, of 11/06/2019, p. 9/52 / 35 as well as the fact that they are raised above the surface. These solid elements may consist, in one case, of soft, elevated shapes, which through their elevated position and solid consistency are suitable as a soft abrasive material for cosmetic purposes, ie exfoliation. High smooth elements, when larger than desired for smooth abrasive purposes, can also be used as non-slip surfaces. In addition, the technique can be used to form patterns of aesthetic appeal in fabric, for decorative purposes. [004] It is known in the art to provide abrasive elements by creating them in finished dry non-woven. As one skilled in the art will recognize, there is also no limitation regarding the shape of the abrasive elements, which can be simple points or can consist of more complex shapes. The degree of abrasion depends on the type of material from which the elements are made (for example, rigid or soft polymer), as well as the density of such elements on the surface (that is, the fraction of the fabric surface that is covered by them) , its shape and its weight.
    [005] US Patent No. 5,213,588 refers to an abrasive cleaning article and a process for its preparation, which involves printing a pattern on a non-woven substrate to create an abrasive product.
    [006] DE 19851878 teaches the preparation of a cleaning article that consists of a non-woven substrate with polymeric particles distributed in it.
    [007] Other ways of creating products of this type involve the application of abrasive elements to a finished fabric. However, creating such abrasive surfaces is expensive because of the need to further process the nonwoven at the end of its manufacturing line. Additionally, due to the nature of the applied solid elements, the amount of material that is required to be deposited in order to obtain
    Petition 870190113726, of 11/06/2019, p. 10/52 / 35 the physical effects required are substantial, making the process not economically viable. This fact so severely limits the usefulness of such fabrics. [008] Therefore, it would be highly desirable to provide a process for the manufacture of non-woven fabrics provided with sparse elements of physical consistency on their surface, without the need for time-consuming and expensive post-processing operations.
    [009] It is an objective of the present invention to provide an in-line process for the manufacture of such improved fabrics, with control over both abrasiveness and pattern height and which overcomes the disadvantages of the prior art.
    [0010] It is an additional objective of the present invention to provide a process, by which only small amounts of the abrasive material are deposited, while retaining control over the level of abrasive properties, whether strong abrasion for cleaning purposes, ie weak abrasion. for cosmetic exfoliation.
    [0011] It is another objective of the invention to provide a process which gives chemical stability to the solid elements after deposition.
    [0012] It is another objective of the invention to provide an in-line process that does not require offline processes or additional elements in the process, while retaining the speed and ease of the manufacturing operation. [0013] It is another objective of the invention to provide finished fabrics of high quality, improved by the addition of elements of physical consistency on its surface.
    [0014] It is another objective of the invention to provide suitable materials to be applied to nonwovens in an in-line process to create solid elements on their surface.
    [0015] Other objectives and advantages of the invention will be apparent as the description proceeds.
    Petition 870190113726, of 11/06/2019, p. 11/52 / 35
    SUMMARY OF THE INVENTION [0016] The invention, in one aspect, relates to a process for the manufacture of a nonwoven on its surface distributed elements having a physical dimension, comprises printing of wet fabric canvas in a desired way using a paste that expands under heating due to an inflating agent contained in it.
    [0017] In another aspect, the invention is directed to a paste suitable for carrying out the process of the invention, which comprises an inflating agent.
    [0018] According to one embodiment of the invention the paste contains a rheology modifier and has a high shear viscosity which is small such that it allows the ink to be transported through the printing unit and distributed to the printer and its movement through of the printing fabric, and a low-shear viscosity that is large enough to prevent the material of the formulation which has been deposited from draining into both the fabric and the sides.
    [0019] In one embodiment, the paste has low-shear viscosity, measured with a Brookfield rotary viscometer at a speed of 1 rpm, from 60,000 to 120,000 cP, preferably from 70,000 to 90,000 cP, and a high viscosity shear, measured with a Brookfield rotary viscometer at a speed of 100 rpm, less than 2,000 cP. In another embodiment, the paste has a medium shear viscosity, measured with a Brookfield rotary viscometer at 60 rpm, from 1,500 to 5,000 cP, preferably from 2,000 to 4,500 cP.
    [0020] Typically, the paste contains a surface tension modifier and a crosslinking agent.
    [0021] According to an embodiment of the invention, the paste contains a total concentration of solid material of 15 to 45% by weight.
    [0022] The paste of the invention is distinguished by a stability of
    Petition 870190113726, of 11/06/2019, p. 12/52 / 35 form defined for a period of at least 5 minutes during which a drop of 1 cm3 of paste dripped in 100 ml of water without stirring maintains its integrity.
    [0023] The invention also encompasses a fabric manufactured by the process of the invention, such as a fabric comprising elements of exfoliation or abrasives on its surface, which are made of the inventive paste.
    BRIEF DESCRIPTION OF THE DRAWINGS [0024] In the drawings:
    Fig. 1 (A to D) is an EMS (Scanning electron microscope) of the surface of a “point” that was created on the surface of a nonwoven, shown in different magnitudes, as indicated in each figure;
    Fig. 2 (A to D) is an EMS of the cross section of the point of Fig. 1, taken in different magnitudes, as indicated in each figure;
    Fig. 3 (A to D) is an EMS of the surface of another “point” that was created on the surface of a nonwoven, shown in different magnitudes, as indicated in each figure;
    Fig. 4 (A to D) is an EMS of the cross section of the point of Fig. 3, taken in different magnitudes, as indicated in each figure;
    Fig. 5 is a graph that summarizes the effect of the concentration of the inflating agent at the point height;
    Fig. 6 is a graph that summarizes the effect of the drying temperature on the point height; and Fig. 7 is a graph that summarizes the effect of ink viscosity on the end point size.
    DETAILED DESCRIPTION OF THE INVENTION [0025] In the description that follows and for the sake of brevity, the process of creating one or more elements of physical consistency on the surface of
    Petition 870190113726, of 11/06/2019, p. 13/52 / 35 a nonwoven will be referred to as "printing", it will be understood that the term is primarily used as an abbreviation and is not intended to limit the invention in any way to any process or apparatus involved in conventional printing techniques or methods related to the deposition of solid elements.
    [0026] By "physical consistency" it is intended to indicate that the elements are not mere decorative impressions, but have their own volume, which extends above the plane of the fabric surface. Likewise, again for the sake of brevity, the elements having physical consistency that are provided on the fabric surface will be referred to below in some cases as "dots", regardless of their actual shape, it will be understood that the definition encompasses any shape and form of said elements. Finally, the materials from which said "points" are made will be referred to below as "paste" or, interchangeably, as "ink", once again to simplify and streamline the description that follows, it will be understood that said reference does not imply any limitation to the type of material used.
    [0027] The present invention provides a process for the manufacture of a nonwoven with abrasive properties of varying level for the purpose of cleaning, from delicate cosmetic cleaning to household cleaning and others. The abrasive nature is conferred to the fabrics through the deposition of high solid elements ("points") and the invention provides methods for determining the abrasive properties of the fabric, by controlling parameters such as, but not limited to point height, size spot density, spot surface density, and spot composition. The point height can be controlled by a number of factors, both from the manufacturing technology as well as from the printing ink composition. The spot size can be controlled by simple physical parameters of the printing process such as the pore size of the printing screen used. In
    Petition 870190113726, of 11/06/2019, p. 14/52 / 35 addition, and more importantly, the spot size is controlled through manufacturing parameters (such as the drying temperature profile) and properties and the composition of the printing ink (such as rheology). The number of dots per surface unit (dot surface density) is controlled by choosing the print mesh and the abrasive level through manufacturing technology factors (such as the drying temperature profile) and composition of printing ink. Control over all these parameters is achieved through the properties of the printing ink and through the manufacturing process, which includes the solid content of the ink, the drying profile, the rheology and thixotropy profile of the ink, the wettability of the ink, and the properties of the components to inflate. By controlling these parameters, several product lines can be obtained, from an abrasive product used for domestic and industrial cleaning having a high degree of abrasiveness, to a softer product suitable for cosmetic cleaning, skin exfoliation.
    [0028] The fabric is a non-woven material, which in the examples described below is one that is manufactured by the technique of hydroentanglement and can consist of different fiber compositions, that is, a combination of absorption fibers such as rayon and cotton, and non-absorbing fibers such as PET and PP. As will be appreciated by the expert, the compositions mentioned here are given for illustrative purposes only and are not intended to limit the invention in any way, it will be understood that any suitable fiber or mix of applicable fibers - as well as any suitable manufacturing process - that can be used to manufacture nonwoven can be used, mutatis mutandis. According to an embodiment of the invention the product is a non-woven tangle with end uses such as cosmetic exfoliation, general cleaning, anti-slip, etc. The fabric in these examples is a standard matted nonwoven material, with variable fiber mix, variable weight and other general variable physical properties, manufactured by N.
    Petition 870190113726, of 11/06/2019, p. 15/52 / 35
    R. Spuntech Industries Ltd., Israel, for a variety of end-use applications.
    [0029] The material that is applied to the nonwoven to create the protrusions will be called "paste formulation" or "ink", for the sake of brevity. A detailed discussion of the paste formulations below will illustrate the components of the formulation. Since the product is intended for various end uses, the properties of the material extending from the fabric surface must be variable and controllable. This is an important advantage of the invention, which allows for flexibility in manufacturing. The most important parameters are: stitch height, stitch size (circumference, if rounded, or another dimension suitable for non-circular shapes), abrasive level, penetration into the fabric, stitch density per unit of surfaces.
    [0030] Paste formulations suitable for use in the present invention have the following common characteristics:
    The. They are all water-based;
    B. They all contain polymer as the base material. This polymer can be chosen from a wide variety of thermoplastic materials, including Polyacrylate; polyurethane, polyesters, etc;
    ç. They all contain an inflating agent, a material suitable for “inflating the protrusion, for example, a point, after they are deposited. This inflating agent consists of microcapsules (made of thermoplastic material such as acrylate), containing alkane gas, for example, isobutane. The microcapsules, when heated, expand by expanding the contained gas (and the extended form is maintained after cooling), and when dispersed in a formulation containing thermoplastic polymer they cause the protrusion to increase significantly in size since the thermoplastic polymer in the formulation maintain its integrity and expand along with the expanding microcapsules. The degree of
    Petition 870190113726, of 11/06/2019, p. 16/52 / 35 size is dependent on the amount of inflating agent added, the thermoplastic properties of the polymer and the temperature at which the assembly is elevated after formation and the person skilled in the art will easily imagine the formulation that satisfies these specific requirements. Inflated microcapsules with variable swelling temperature ranges are available on the market and are well known to those skilled in the art;
    d. All of them contain rheology modifiers that are crucial to obtain the correct rheological behavior of the paint formulation during the various stages of the process. The control of rheology is of great importance to obtain the physical elements with the desired properties. Main requirements:
    1. The viscosity at medium shear levels must be such that the formulation can be easily handled and transported without the need for special equipment;
    2. The high shear viscosity must be low in a degree that allows the ink to be transported through the printing unit and distributed to the printer and its movement through the printing screen;
    3. The low-shear viscosity must be high enough to prevent material from the formulation which has been deposited from draining into both the fabric and the sides. The behavior described above, which in professional terms is called “thixotropy”, is an important element of the invention. Representative appropriate viscosity levels are: low shear (measured with a Brookfield rotary viscometer at a speed of 1 rpm): from 60,000 to 120,000 cP, and preferably from 70,000 to 90,000 cP; high shear (measured with a Brookfield rotary viscometer at 100 rpm): below 2,000 cP; and medium shear (measured with a Brookfield rotary viscometer at 60 rpm); from 1,500 to 5,000 cp, preferably from 2,000 to 4,500 cp;
    Petition 870190113726, of 11/06/2019, p. 17/52 / 35
    and. All of them contain additives to modify the surface tension of the deposited physical element. The surface tension, when sufficiently large, prevents a bead or thread or any other form that forms the physical element, after deposit, but before the temperature is applied it is diluted and dissolved in water that is present in the base fabric as a result of the tangle process. The amount of water present in the base fabric can vary (depending on the process parameters and the fiber composition of the fabric) and typically ranges from 50 to 80% of the dry tissue weight, to 100 to 200% of the dry tissue weight;
    f. They all contain a crosslinking agent to allow accelerated crosslinking of the polymer used as well as crosslinking to the fabric for additional stability of the physical elements in the fabric;
    g. Optionally, all of them can contain dyes or other materials for aesthetic improvement depending on the application and the user's desire;
    H. all of them are formulations in a concentration of 15 to 45% by weight solid material, in which the amount of solid material depends on the desired application;
    [0031] A number of properties of the printing folder determines the behavior of the folder before, during and after printing, and control over these properties will allow control of the properties of the end points. The main properties that need to be controlled for the process to proceed properly are:
    The. the solid content;
    B. the rheology and thixotropy profile;
    ç. wettability;
    d. the polymer and filler properties; and
    and. the properties of the inflating component.
    [0032] The solid content of the paste formulation influences
    Petition 870190113726, of 11/06/2019, p. 18/52 / 35 directly the amount of water that needs to be removed from the physical element during the drying process and thus the amount of energy needed to remove this water. The amount of solids in the ink also determines the “Complement” during printing, that is, the amount of wet paste that the printing machine transfers to the fabric in order to achieve the desired amount of solids in the fabric. This determines the maximum amount of solids that can be transferred to the fabric at a given speed and is thus a factor limiting the speed of the manufacturing process. For applications where a larger amount of solid element needs to be deposited, a larger solid content is preferably used. As stated, typical solid contents will be in the range of 15 to 45% by weight while the application and percentage coverage of the physical element in the fabric will determine the optimum solid content. For physical elements with a greater coverage, a larger solid content is desirable to be able to maintain production parameters such as speed, abrasive level and cost.
    [0033] The rheology profile of the printing ink, when it moves through the printer, flowing through the screen and being deposited on the fabric, is important to obtain the necessary properties of the dry point and final print. The basic paint formulation itself is already thixotropic and its thixotropic behavior can be further improved through the use of additives. When being pumped from the holding vessel to the screen, the pump pressure keeps the viscosity low enough to allow essentially free laminar flow and also the exit through the screen pores is facilitated by its low viscosity at high shear. Once the ink reaches the fabric, and no pressure is exerted anymore, the viscosity (which is now in very low shear), increases significantly, and this stabilizes the dot printed on the fabric and minimizes both lateral flow and penetration. on the fabric. How thixotropic behavior
    Petition 870190113726, of 11/06/2019, p. 19/52 / 35 of the paint dictates both the high and low shear viscosity, as well as the gap between them, the optimal values need to be determined experimentally. In fact, the viscosity of the printing ink at various stages of the printing process determines the characteristics of the dots as follows:
    1. High shear viscosity [0034] The ink must be able to flow freely through the printing unit and into the screen printing system under the pressure of the pump that supplies the ink to the printing unit. In order to allow this flow, the high shear viscosity of the paint must be low enough (1,000 to 2,000 cP at 100 rpm in Brookfield viscometer). The high shear viscosity should not be too high to avoid clogging the printing system, in particular screen printing.
    2. Low shear viscosity [0035] After the ink leaves the printing screen and is deposited on the fabric as a dot, no force is exerted on it and the flow properties of the ink can cause both the penetration of the ink into the fabric (thereby reducing forms the height of the final printed dot as well as making the dot protrude from the back side of the fabric) as well as the lateral flow of the ink (which should also reduce the height of the final printed dot and, through the lateral flow also its size). An increase in low shear viscosity will limit these effects. However, if too high a low-shear viscosity (above approximately 90,000 cP in lrpm in a Brookfield viscometer) will prevent proper ink deposition on the fabric and cause a reduction in height and less attachment. To overcome the problems described above, the paint is designed to be thixotropic in nature with defined low and high shear viscosities.
    [0036] The paste printing formulation according to the invention
    Petition 870190113726, of 11/06/2019, p. 20/52 / 35 is a stable water-based emulsion of polymeric material and additives. As printing is done on damp fabric, the contact of the paste with the wet fabric can immediately result in the dilution of the printing paste, which can induce changes in the behavior of the rheology and flow of the printed material. To avoid this problem the wettability of the printing paste is controlled using suitable additives to increase the surface tension of the wet spot surface to a level that the mixing shear is necessary to “dilute” the wet printed point and very little mixture of the paste. printed with water on the fabric occurs.
    [0037] The inflating agent is added to the formulation in an amount sufficient to increase the size of the physical element (that is, the final protrusion) to the desired level. Control over the increase in size is obtained through the energy supplied to the solid element (through the drying temperature).
    [0038] Specific paste formulations are employed according to the intended purpose of the fabrics. An example of the paste formulation used in a fabric modality of the invention for home and industrial cleaning purposes, where a high degree of abrasiveness is required, comprises a basic polymeric material, such as polyacrylate, polyurethane or the like; a rheology modifier; an inflating agent; a chemical agent to control surface stresses; a dye; an inorganic filler; a cross-linking agent; and water. Another example of paste formulations, used in a fabric embodiment of the invention for cosmetics, comprises a base polymeric material, such as polyacrylate, polyurethane or other suitable; a rheology modifier; an inflating agent; a chemical agent to control surface stresses; a dye; a fixing agent; and water.
    Test Method to establish the amount of surface active agents needed in the formulation.
    Petition 870190113726, of 11/06/2019, p. 21/52 / 35 [0039] The presence of surface active agents in the formulation is necessary to maintain the integrity of the stitch after printing on damp fabric. The formulation contains 60% water, but the surface active agents should avoid mixing the formulation with the water on the printing surface (water contained in the fabric, which can reach 200% by weight of the fabric).
    [0040] A wide variety of surface active agents can be used and a simple test can be performed to establish the effectiveness of the agent used. A 1 cm 3 amount of the printing ink is dripped into 100 ml of water without stirring. If the drop maintains its integrity for at least a period of 5 minutes (without agitation), the surface active agents are sufficient for the purpose of the invention, to avoid mixing the formulation with water on the printing surface to any degree .
    General manufacturing procedure [0041] In one embodiment of the invention, the printing of a paste formulation on the fabric is performed using the online printing technology described in WO2004 / 071780 from the same depositor here, although alternative systems can be employed. In this particular embodiment of the invention, printing is done using a standard screen printer (Stork BV, Netherlands), which is positioned on the tangle manufacturing line behind the water removal suction boxes and before the fabric reaches the dryers (ie , printing is done on fabric that is still damp), as described in WO2004 / 071780 mentioned above. The ink formulation dictates its behavior before reaching the fabric, during deposition on the fabric and after deposition and before drying. The physical element, be it a stitch, a line or any other type of pattern, is printed on the damp fabric and the printed fabric is transferred to the dryer.
    [0042] The fabric with the printed physical element can be dried together
    Petition 870190113726, of 11/06/2019, p. 22/52 / 35 with the fabric at a single temperature level of the dryer oven, which must be high enough that: 1) the fabric is dry; 2) the physical element is dry; 3) the physical element reaches the temperature required for the “inflation” of the printed form. The temperature of the fabric and / or the printed element must not reach above 160 ° C to prevent over-extension and rupture of the inflating microcapsules, which must cause the collapse of the physical element and result in a severe reduction in the height of the element physical as well as destroying the smooth surface of the physical element.
    [0043] In another embodiment of the invention, a stage drying oven can be used, in which in the first stage the temperature is maintained at 110 to 120 ° C to allow the fabric and the physical element to dry, while in a second stage the temperature is allowed to reach up to 150 ° C to allow the physical element to “inflate” to its maximum height while maintaining integrity. Here, too, the temperature must not be allowed to exceed 150 ° C to avoid breaking the physical element with a resulting reduction in the height of the protrusion and destruction of the smooth surface. These stages can also be combined in an ongoing process.
    [0044] In both modes discussed above, during the drying process the temperature is high enough to allow the activation of the fixing agent and to ensure that the crosslinking of the polymer itself and to the fabric is completed during this step. After leaving the dryer the product is finished and can be rolled and cut to size.
    [0045] To summarize, the drying profile needs to address two main requirements. First the removal of water from the tissue and the protrusion in order to dry the paste, and second, inflate the protrusion to the desired height, by activating the inflating agent, which starts at a predetermined temperature. Thermal energy needs to be supplied in the correct proportions during the fabric residence time in the dryer to
    Petition 870190113726, of 11/06/2019, p. 23/52 / 35 obtain optimal results. Alternatively, a one-step drying process can be employed at a temperature high enough to allow the microcapsules to expand while simultaneously drying the tissue and controlling the height of the physical element. An expert will easily imagine that the temperature - residence time ratio required for the desired processing. The inflating agent will typically be activated at a temperature of approximately 121 to 145 ° C (products inflated with different activation temperatures are also available and everything stated here regarding the inflating agent employed for the illustrative examples is applicable, mutatis mutandis, for the other inflating agents by adjusting the temperature accordingly) and up to a limit of approximately 150 ° C, the amount of energy supplied to the inflating agent will determine the rate and extent of expansion and thus the final temperature of the protrusion that will be obtained. Thus, the drying temperature should be such that the fabric will be dried and in addition, according to the desired height of the solid element.
    [0046] As stated above, the maximum temperature that the printed physical element can be exposed to is 150 ° C, so as not to cause the rupture and with this, the destruction of the physical element. However, as the residence time of the printed fabric in the dryer system is short, at high manufacturing speeds, a dryer temperature setpoint can be significantly greater than 150 ° C, just to ensure that the fabric and element printed matter will reach temperatures up to 150 ° C.
    EXAMPLES [0047] The following examples will describe the fabric manufacturing process of the invention and illustrate how the factors described above influence control over the characteristics of the final product. In all examples the fabric is a non-woven material manufactured by the hydroentanglement technique and also consists of different fiber compositions, that is, a
    Petition 870190113726, of 11/06/2019, p. 24/52 / 35 combination of absorbent fibers such as rayon and cotton, and non-absorbent fibers such as PET and PP. In all examples, the dots are printed using the line printing technology described in WO2004 / 071780 from the same depositor here, although alternative systems may be employed. In this particular embodiment of the invention, printing is done using a standard screen printer (Stork BV, Netherlands), which is positioned on the tangle fabrication line behind the water removal suction boxes and before the fabric reaches the dryers (ie ie, printing is done on the fabric which is still damp), as described in WO2004 / 071780 mentioned above.
    Example 1
    Influence of the solid content of a paste formulation [0048] A 60gsm fabric was manufactured as described above with a blend of 30% Viscose and 70% PET fibers and dots were printed on the wet fabric using a screen printer as described above . The ink formulation, “Formulation A”, is used for printing. The basic paste formulation called “Formulation A” consists of two different acrylic copolymers supplied by BASF (Germany) (ACRONAL LN 579 S and ACRONAL S-537 S) 21.3% and 12.9% respectively; and a variety of additives for various purposes: urea (wetting agent, 0.75%); Dietylene Glycol (Processing aid, 0.02%); Trimethylpropane tris (2-methyl-laziridine-propionate (Crosslinking agent (0.4%); C9-C11 polyethoxylated alcohol (Rheology agent and 0.16% emulsifier)); C16-C18 polyethoxylated stearyl alcohol (Rheology agent and emulsifier, 1.51%); Sodium lauryl sulfate (Rheology and emulsifying agent, 1.17%); Defoaming agents, which include Polydimethyl Siloxane and Silica and Preservative agents that may include Sodium benzoate, Methyl-iso Thiazoline and Methyl -Chloro-iso-thiazoline The formulation is made up to the desired solid content through the addition of water.
    Petition 870190113726, of 11/06/2019, p. 25/52 / 35 [0049] The basic formulation was finalized by the addition of inflating Microcapsules (Expancel 031WUFX 40, supplied by AKZO Nobel, Sweden) to a level of approximately 5% weight by weight. (which is approximately 11.5% by weight of polymer solids).
    [0050] The viscosity of the formulation was adjusted with a rheology modifier (polyacrylic acid ammonium salt (AVCOCLEAR 150, supplied by AVCO Chemicals, Israel)), to 4,000 cP (measured at 60 rpm with a HAAKE portable viscometer).
    [0051] A specially developed screen was used: O.A. (Open area, that is, the percentage of screen area occupied by the pores) 3.6%; thickness: 200 gm; pore size: 0.50 mm; WPV: 7.2. Three runs were made in which the solid content of the printing ink varied from 43.3% solids, up to 37.7% and then to 34.0%. In all three solid cases of 4.3 gsm were deposited on the fabric and the adjustment for the Inflating concentration and viscosity were made to ensure identical values in each run.
    [0052] The stitch characteristics are given in Table 1 below:
    Table 1
    Sample No. Solid content (%) Fabric thickness (micron) Spot size (mm) 1 (43.3) 0.90 0.9 2 (37.7) 0.82 to 0.84 0.9 to 1.0 3 (34.0) 0.79 1.2
    [0053] The solid content of the ink formulation directly affects the amount of material that is added to the fabric when the same canvas (with the same print volume) is used. As shown above, when the same volume of material is deposited using formulations with a different solid content, the greater solid content will deposit greater amounts of material on the fabric and will result in greater, but less expanded (smaller diameter) protrusion. Thus, the solid content of the ink formulation can be used to regulate the amount of material deposited while using the same printing screen.
    Petition 870190113726, of 11/06/2019, p. 26/52 / 35
    Example 2
    Influence of the rheology and thixotropy profile of a paste formulation [0054] Table 2 shows the viscosity profiles of four different printing inks that were used in the different work examples.
    [0055] All paste compositions are made from Basic Formulation B. The basic paste formulation called Formulation B consists of two different acrylic copolymers supplied by BASF (Germany) (ACRONAL LN 579 S and ACRONAL S-537 S) 21.3% and 12.9% respectively; an inflating agent, polymeric microcapsules containing an expanding gas ie isobutane, supplied by AKZO Nobel (Sweden) (Expancel 031WUFX 40, 5%) and a variety of additives for various purposes: urea (wetting agent, 0.75 %); Dietylene Glycol (Processing aid, 0.02%); Trimethylpropane tris (2-methyl-1-aziridine-propionate (Crosslinking agent (0.4%); C9-C11 polyethoxy fatty alcohol (Rheology and emulsifying agent 0.16%)); C16-C18 polyethoxylated stearyl alcohol (C16-C18 Rheology and emulsifier, 1.51%); Sodium lauryl sulfate (Rheology agent and emulsifier, 1.17%); Defoaming agents, including Polydimethyl Siloxane and Silica and Preservative agents that may include Sodium benzoate, Methyl-iso Thiazoline and Methyl-Chloro-iso-Thiazoline The solid content of the formulation can be modified by adding water The standard solid content is 42.8% weight by weight.
    [0056] The viscosity of these four samples was adjusted by variations in the amount of rheology modifier added and the overall viscosity was checked using polyacrylic acid ammonium salt (AVCOCLEAR 150, supplied by AVCO Chemicals, ISRAEL).
    Petition 870190113726, of 11/06/2019, p. 27/52 / 35
    Table 2
    Sample number 57 62 59 61 Solid content 35.0 34.9 35.4 40.3 Low shear viscosity (1 rpm) 31000 45000 70000 110000 Medium shear viscosity (50 rpm) 5500 5500 5500 5800 High shear viscosity (100 rpm) 4000 3150 3150 3800 Thixotropy ratio (1 rpm / 50 rpm) 5.6 8.2 12.7 19.0
    [0057] Viscosity measurements were performed using a Brookfield rotary viscometer. In the examples below, the CP 10 printing screen was used with a pore size of 0.55 mm.
    Example 2A [0058] A 59gsm fabric was manufactured as described above with a blend of 50% Viscose and 50% PET fibers and dots were printed on the wet fabric using a screen printer as described above. Ink formulation 57 with the rheology profile given above was used for printing. The printed dots had a size (diameter) of 1.2 to 1.3 mm and the fabric thickness was 0.71,
    Example 2B [0059] A 59gsm fabric was manufactured as described above with a blend of 50% Viscose and 50% PET fibers and stitches were printed on the wet fabric using a screen printer as described above. Ink formulation 62 with the rheology profile given above was used for printing. The printed dots had a size (diameter) of 1.0 mm and the fabric thickness was 0.74.
    Example 2C [0060] A 59gsm fabric was manufactured as described above with a blend of 50% Viscose and 50% PET fibers and dots were printed on the wet fabric using a screen printer as described above. Ink formulation 59 with the rheology profile given above was used for printing. The printed dots had a size (diameter) of approximately 1.0 mm and the fabric thickness was 0.75.
    2D Example [0061] A 59gsm fabric was manufactured as described above with the
    Petition 870190113726, of 11/06/2019, p. 28/52 / 35 fiber blend of 50% Viscose and 50% PET and dots were printed on the wet fabric using a screen printer as described above. The ink formulation 61 with the rheology profile given above was used for printing. The low shear viscosity is very high and no impression could be made.
    [0062] The results obtained in examples 2A to 2D are summarized in Table 3 below.
    Table 3
    Formulation(thixotropy ratio) Screen Spot size (diameter) Fabric thickness Deposited material ( g sm) 57 (05.6) CP 10 / 0.55 Approximately 1.3 mm 0.71 mm 2.1 62 (08.2) CP 10 / 0.55 Approximately 1.1 mm 0.74 mm 2.1 59 (12.7) CP 10 / 0.55 Approximately 1.0 mm 0.75 mm 2.1 61 (19.0) CP 10 / 0.55 - - -
    [0063] The results clearly show that the increased thixotropy ratio contributes to a smaller point with a higher height. However, both the low shear viscosity and the high shear viscosity must be kept in a specific range to ensure proper operation of the printing process.
    Example 3
    Influence of drying temperature [0064] In the examples below, the effect of temperature on the dryer on the point characteristics can be seen.
    [0065] A 55 gsm fabric was manufactured using a blend of standard 40% Viscose and 60% PET matting technology fibers and dots were printed on the finished fabric, but not dried using a screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    Formulation B: 200 Kg
    NWB Blue: 1.5 Kg (Copper Phthalocyanine Blue, Alpha Form)
    Water: 6.0 Kg
    AVCOCLEAR 150: 0.5 Kg (Acid ammonium salt
    Petition 870190113726, of 11/06/2019, p. 29/52 / 35 polyacrylic) [0066] This formulation has a solid content of 38.9% and a viscosity of 2,900 cP (at 60 rpm), as measured with a portable HAAKE viscometer. Five samples were run with this printing ink, with temperature increasing from the dryer: 112, 127, 141, 156 and 171 ° C respectively. The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm. For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the line speed (printing speed) was adjusted to 71.6 m / min. Samples were collected from all five print runs and the spot height and spot diameter were measured. The results are reported in Table 4 below:
    Table 4
    Sample number 4 5 6 7 8 Dryer temperature (° C) 112 127 141 156 171 Thickness (mm) 0.70 0.77 0.79 0.79 0.76 Point height (mm) 0.14 0.21 0.23 0.23 0.20 Spot diameter (mm) 0.9 to 1.0 1.0 1.0 1.0 1.0
    [0067] The dryer temperature reaches an optimum at about 150 ° C, with the maximum stitch height, after which the stitch height begins to decrease. This is to maintain the activation temperature of the inflating compound, which is between 121 to 145 ° C. The dot diameter does not change, which indicates that the viscosity of the printing ink is such that the dot does not spread after printing and the expansion is in the vertical direction only, while there is sufficient strength of the fabric (as a result of the viscosity) that penetration is not increased and that the expansion by the points is directed outwards.
    Example 4
    Use of different thread speeds [0068] A 55 gsm fabric was manufactured using a blend of standard 40% Viscose and 60% PET matting technology fibers and dots were printed on the finished fabric, but not dried using a
    Petition 870190113726, of 11/06/2019, p. 30/52 / 35 screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    Formulation B: 200 Kg
    NWB Blue: 1.5 Kg Water: 6.0 Kg AVCOCLEAR 150: 0.5 Kg [0069] This formulation has a solid content of 38.9% and a viscosity of 2,900 cP (at 60 rpm), as measured with a portable viscometer HAAKE. Four samples were run with this printing ink, with increasing line speed: 72.3, 93.8, 113.9 and 134.4 m / min. respectively. The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm. For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the dryer temperature was adjusted to 140 ° C. Samples were collected from all four print runs and point height and point diameter were measured. The results are summarized in Table 5 below:
    Table 5
    Sample number 9 10 11 12 Line speed (m / min) 72.3 93.8 113.9 134.4 Thickness (mm) 0.81 0.81 0.82 0.82 Point height (mm) 0.25 0.25 0.26 0.26 Spot diameter (mm) 1.0 1.0 1.0 1.0
    [0070] Neither the Point Height nor the Point Diameter are significantly increased by line speeds. The printing process is stable and can be run at variable speeds as needed.
    Example 5
    Use of different printing fabrics [0071] A nonwoven with 50% PET and 50% Viscose fiber composition, was manufactured using standard Tangle techniques and stitches were printed on the fabric in a random pattern before the nonwoven was dried, using a screen printer and general technology as described above.
    Petition 870190113726, of 11/06/2019, p. 31/52 / 35 [0072] The fabric before printing had a weight of 53 gsm.
    [0073] The screen printer has been adjusted consecutively with three different screens, which have different pore density:
    CP8: pores with 0.50mm; 200 micron thickness; Open area: 1.9%; WPV: 3.8
    CP12: 0.45mm pores; 200 micron thickness; Open area: 2.2%; WPV: 4.4
    CP24: 0.45mm pores; thickness 160 microns; Open area: 4.3%; WPV: 6.9 [0074] The paste used was from Formulation B with AVCOCLEAR added to adjust the viscosity (at 60 rpm) to 4,000 cP; Solid content: 42.8%.
    [0075] A single stage dryer was used in which it was set at 145 ° C.
    Example 5a: CP8 screen [0076] Printing started at the 6.0 cm 3 / m 2 complement (wet paste volume per square meter of fabric) (which is approximately 2.4 gsm solids deposited on the fabric and constitutes 159% of the wet paste volume of the fabric)) Fabric weight after printing: 55.5 gsm. The points are well developed and have significant height (approximately 250 μηι). Spot size: approximately 1.0 mm
    Example 5b: Screen CP12 [0077] Printing started at Complement 7.0 cm 3 / m 2 (wet paste volume per square meter of fabric). (Which is approximately 2.8 gsm solids deposited on the fabric which makes up 159% of the wet paste volume of the fabric)) A good quality fabric is obtained and a roll has been manufactured under these conditions. Fabric weight after printing: 56.0 gsm. The points are well developed and have significant height (approximately 250 μm). Spot size: approximately 1.0 mm
    Petition 870190113726, of 11/06/2019, p. 32/52 / 35
    Example 5c: Screen CP24 [0078] Printing started at Complement 11.0 cm 3 / m 2 (volume of wet paste per square meter of fabric). (which is solids of approximately 4.4 gsm deposited on the fabric that constitutes 159% of the wet paste volume of the canvas)). Under these conditions a roller was manufactured. Fabric weight after printing: 56.2 gsm (The base weight has been reduced to 51 gsm for this product). The points are well developed and have significant height (approximately 250 μηι). Stitch size: approximately 1.0 mm [0079] Table 6 below provides the physical properties of the fabric obtained in the example above.
    Table 6
    CP8 screen CP12 screen CP24 screen Dry MD resistance (N / 5 cm) 132.7 140.3 144.7 Wet MD resistance (N / 5 cm) 138.0 133.0 149.1 Dry CD resistance (N / 5 cm) 31.9 33.5 33.3 Wet CD resistance (N / 5 cm) 37.4 37.2 36.6 Elongation MD (%) 38.0 41.2 39.0 Elongation CD (%) 103.2 110.4 116.0 Weight (gsm) Wet 54.4 54.9 55.1 dry 52.4 52.8 52.6 Thickness (mm) 0.85 0.84 0.85 Capillarity Machine direction 34.6 27.6 28.8 (mm / 10sec) Transverse direction 21.8 21.2 21.2 Absorption (g / g) 9.8 9.8 10.2
    Example 6
    Use of different drying processes
    Example 6A Multistage drying process [0080] A nonwoven with a fiber composition of 50% PET and 50% Viscose, was manufactured using standard Tangle techniques and stitches were printed on the fabric in a random pattern before the nonwoven was dry using a screen printer and general technology as described above. The fabric before printing had a weight of 55.5 gsm. CP 10 Screen was used for printing: CP 10: Pore size: 0.50; 2.3% OA; WPV: 4.6 cm 3 / m 2 ; 200 μm thickness. The paste used was from Formulation B with the following characteristics: Viscosity (at 60 rpm): 2,600 cP; Solid content:
    Petition 870190113726, of 11/06/2019, p. 33/52 / 35
    42.8%. The line was run at a speed of 105 m / min. A multistage dryer was used with the following settings:
    Table 7
    Dryer Temperature (° C) Dryer 1 140 Dryer 2 145 Dryer 3 120 Dryer 4 130 Dryer 5 120 Dryer 6 110
    [0081] Printing started at the 6.0 cm 3 / m 2 complement (wet paste volume per square meter of fabric), which is a solid 2.6 gsm deposited on the fabric at 130% wet paste volume. The printed dots were well formed with a thickness of approximately 250 qm and a dot size of 0.9 mm. Note: The fabric moves through the oven segments in the following order: 6-5-4-1-2-3. The fabric weight after printing was 58.5 gsm. Table 8 below shows the physical characteristics of the fabric manufactured. The two columns represent two different samples collected during the race.
    Table 8
    Product designation 13 Paste formulation B B MD resistance (N / 5 cm) (wet) 131.9 136.6 Resistance CD (N / 5 cm) (wet) 39.2 39.4 Elongation MD (%) (wet) 34.2 36.8 Elongation CD (%) (wet) 111.4 94.6 Weight (gsm) Wet 57.4 57.7 dry 55.2 55.4 Thickness (mm) 0.78 0.79 Capillarity MD - - (mm / 10sec) CD - - Absorption (g / g) 9.6 9.7
    Example 6b: Single stage drying process [0082] A nonwoven with 65% PET and 35% Viscose fiber composition, was manufactured using tangle pattern techniques and stitches were printed on the fabric in a random pattern before the nonwoven be dried using a screen printer and general technology as described above. The fabric before printing had a weight of 85.0 gsm. The CP24 screen was used for printing: CP24 / 0.45: 4.3% OA; WPV 6.9 cm 3 / m 2 ; Thickness 160 qm; Pore size 0.45 mm. The paste used was from Formulation B with
    Petition 870190113726, of 11/06/2019, p. 34/52 / 35 the following characteristics: Viscosity (at 60 rpm): 4,000 cP; Solid content: 42.8%.
    [0083] A one stage dryer was used set at 140 ° C. The line was run at a speed of 75 m / min. The impression was made in the complement 15.0 cm 3 / m 2 (volume of wet paste per square meter of fabric), which is a solid of 6.4 gsm deposited on the fabric in the Wet Paste Volume of 217%. The printed dots were well formed with a thickness of approximately 200 pm and a dot size of 1.0 mm. Fabric weight after printing was 91.0 gsm. Table 9 below shows the physical characteristics of the fabric manufactured.
    Table 9
    Dry MD resistance (N / 5 cm) 194.6 Wet MD resistance (N / 5 cm) 207.2 Dry CD resistance (N / 5 cm) 52.4 Wet CD resistance (N / 5 cm) 55.4 Elongation MD (%) 42.0 Elongation CD (%) 125.4 Weight (gsm) Wet 89.6 dry 87.4 Thickness (mm) 1.05 Capillarity (mm / 10sec) MD 30.6 CD 87.4 Absorption (g / g) 8.0 Deposited solids (gsm) 6.9
    Example 7 [0084] The following are examples of the nonwoven fabrication process with physical elements (dots) printed on it.
    Example 7 a:
    [0085] A non-woven with a base weight of approximately 46 gsm (grams per square meter) is manufactured with a fiber composition of 10% Rayon, 70% PET and 10% Cotton using tangle technology. Before the fed fabric is fed to the dryer, but after the suction boxes which remove significant amounts of water from the fabric, a screen printer is used to print a dot pattern on the fabric, using a CP30 coded screen which has a thickness 160 microns, 0.45 mm pore size. Open area is 5.1% and the WPV of the Screen
    Petition 870190113726, of 11/06/2019, p. 35/52 / 35 is 8.16 cm 3 / m 2 . (manufactured by Stork, Austria). The printing ink used is Formulation B with added white dye (5% weight by weight) (TiO2, which is supplied as a water based paste of 70% solids by AVCO Chemicals, Israel). This brings the solid content of the printing ink to 43.7%. Viscosity was adjusted to 4,200 cP using AVCOCLEAR 150.
    [0086] Using this formulation 6.2 gsm of solids were deposited on the tissue.
    [0087] The height of the stitch pattern obtained was approximately 350 microns.
    Example 7b:
    [0088] A non-woven with a base weight of approximately 55 gsm is manufactured with a fiber composition of 50% Rayon, 50% PET using tangle technology. Before the fed fabric is fed to the dryer, but after the suction boxes which remove significant amounts of water from the fabric, a screen printer is used to print a dot pattern on the fabric, using the CP 10 coded screen which has a 200 micron thickness, 0.45 mm pore size. Open area is 1.8% and WPV is 3.6 cm 3 / m 2 (manufactured by Stork).
    [0089] The printing ink used is that of Formulation B with added white dye (5% weight by weight) (TiO2, which is supplied as a water based paste of 70% solids by AVCO Chemicals, Israel). This brings the solid content of the printing ink to 43.7%. The viscosity was adjusted to 3,000 cP using AVCO CLEAR 150. The low shear viscosity (at 1 rpm) is 85,000 cP.
    [0090] Using this formulation 2.55 gsm of solids were deposited on the tissue.
    [0091] The height of the stitch pattern obtained was approximately 350 microns.
    Example 7c:
    Petition 870190113726, of 11/06/2019, p. 36/52 / 35 [0092] A non-woven with a base weight of approximately 64 gsm is manufactured with a fiber composition of 30% Rayon, 70% PET using tangle technology. Before the fed fabric is fed to the dryer, but after the suction boxes which remove significant amounts of water from the fabric, a Screen printer is used to print a Random Lines pattern on the fabric, using an RL2 / CH60 coded screen which has a thickness of 190 microns, pore size of 0.313 mm. Open area is 14.76% and WPV is 9.04 cm 3 / m 2 (manufactured by Stork.) [0093] The printing ink used is Formulation B with added blue dye (0.8% weight by weight) Copper phthalocyanine blue, Form alpha). This brings the solid content of the printing ink to approximately 40.4%. The viscosity was adjusted to 3,800 cP using AVCOCLEAR 150.
    [0094] Using this formulation 6.5 gsm of solids were deposited on the tissue.
    [0095] The height of the stitch pattern obtained is approximately 300 microns.
    Example 8
    Particle Morphology Study
    Example 8 a:
    [0096] Using the process of Example 2c a tissue was manufactured and then analyzed using an electron microscope. Figs. 1 and 2 are electron microscope scans of a sample designated 59. Figs. 1A to ID are figures of the sample surface, taken in different magnitudes, as indicated in each figure. The “point” is indicated by the numeral 100 in Fig. 1A. the figures show the holes in the particle surface where gas escaped during the inflation stage.
    [0097] Fig. 2 is a cross section of the point of Fig. 1, taken along the plane A - A of Fig. 1A, again in different magnitudes, as
    Petition 870190113726, of 11/06/2019, p. 37/52 / 35 indicated in each figure. As can be seen in the figures, the polymer that forms the stitch has penetrated the nonwoven, thus securely attaching itself to it.
    Example 8b:
    [0098] Another sample was made using the process of Example 7c, and then was analyzed using the electron microscope. Figs. 3 and 4 are Electron microscope scans of a sample designated 64. Figs. 3A through 3D are images of the show surface, taken in different magnitudes, as indicated in each figure. The “point” is indicated by the numeral 300 in Fig. 3A. It can be seen in the figures that fewer holes appear on the surface of the particle where gas escaped during the inflation stage, due to a more gentle inflation process carried out by maintaining a lower temperature during the process.
    [0099] Fig. 4 is a cross section of the point of Fig. 3, taken along the plane B - B of Fig. 3A, again in different magnitudes, as indicated in each figure. Here again, and particularly in Fig. 4B, it is easy to see how the polymer that forms the point has penetrated the nonwoven, thus securely attaching itself to it.
    Example 9
    Effect of Inflating Concentration as a function of total amounts of solids [00100] A 55gsm fabric was manufactured using standard weaving technology: mixture of 40% Viscose fibers and 60% PET and dots were printed on the finished fabric, but do not dry using a screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    Formulation A: 200 Kg
    NWB Blue: 1.5 Kg
    Water: 5.5 Kg
    Petition 870190113726, of 11/06/2019, p. 38/52 / 35
    AVCOCLEAR 150: 0.4 Kg [00101] This formulation has a solid content of 38.6% and a viscosity of 3,100 cP (at 60 rpm), as measured with a portable HAAKE viscometer.
    [00102] Four samples were run with this printing ink, the first with the ink as it is, and then after adding the increasing amounts after adding increasing amounts of inflating compound (6.08, 11.47, and 16.23% respectively, based on the solids in the formulation, which is approximately 2.5, 5, and 7.5% based on the total formulation weight). The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm.
    [00103] For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the line speed (print speed) was adjusted to 72.8 m / min and the temperature dryer was set to 140 ° C. Samples were collected from all four print runs and point height and point diameter were measured. The results are detailed in Table 10 below:
    Table 10
    Sample 14 15 16 17 Inflating concentration (%) 0 6.08 11.47 16.23 Thickness (mm) 0.56 0.66 0.74 0.85 Point height (mm) Approximately 0 0.10 0.18 0.29 Spot diameter (mm) 0.8 to 1.0 1.0 1.0 1.0
    [00104] As seen in Fig. 5, the point height increases (almost) linearly with the increase of the Inflating Concentration, while the diameter of the points remains unchanged. This experiment clearly shows that inflation creates the point height and that this point height increases linearly with the amount of inflation in the printing ink. The dot diameter does not change which indicates that the viscosity of the printing ink is such that the dot does not spread after printing and the expansion is in the vertical direction only, while there is sufficient resistance of the fabric (as a result of the viscosity) that penetration is not increased and that expansion by
    Petition 870190113726, of 11/06/2019, p. 39/52 / 35 points is directed outward.
    Example 10
    Effect of Dryer Temperature on Stitch Height and Diameter [00105] A 55gsm fabric was made using a blend of standard 40% Viscose and 60% PET matting technology fibers and dots were printed on the finished fabric, but not dry using a screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    Formulation B: 200 Kg
    NWB Blue: 1.5 Kg
    Water: 6.0 Kg
    AVCO CLEAR 150: 0.5 Kg [00106] This formulation has a solid content of 38.9% and a viscosity of 2,900 cP (at 60 rpm), as measured with a portable HAAKE viscometer.
    [00107] Five samples were run with this printing ink, with increasing dryer temperature: 112, 127, 141, 156 and 171 ° C respectively. The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm. For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the line speed (printing speed) was adjusted to 71.6 m / min. Samples were collected from all five print runs and point height and point diameter were measured. The results are detailed in Table 11:
    Table 11
    Sample 18 19 20 21 22 Dryer temperature (° C) 110 125 140 155 170 Thickness (mm) 0.70 0.77 0.79 0.79 0.76 Point height (mm) 0.14 0.21 0.23 0.23 0.20 Spot diameter (mm) 0.9 to 1.0 1.0 1.0 1.0 1.0
    [00108] As shown in Fig. 6, the dryer temperature reaches an optimum at about 150 ° C, with the maximum point height, after which the
    Petition 870190113726, of 11/06/2019, p. 40/52 / 35 stitch height starts to decline. This is in keeping with the activation temperature of the inflating compound, which is between 121 and 145 ° C. The dot diameter does not change, which indicates that the viscosity of the printing ink is such that the dot does not spread after printing and the expansion is in the vertical direction only, while there is sufficient strength of the fabric (as a result of the viscosity) that penetration is not increased and that the expansion by the points is directed outwards.
    Example 11
    The effect of line speed on stitch height and Stitch diameter [00109] A 55gsm fabric was manufactured using a blend of standard 40% Viscose and 60% PET matting technology fibers and stitches were printed on the finished fabric, but do not dry using a screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    HDP-5: 200 Kg
    NWB Blue: 1.5 Kg
    Water: 6.0 Kg
    AVCOCLEAR 150: 0.5 Kg [00110] This formulation has a solid content of 38.9% and a viscosity of 2,900 cP (at 60 rpm), as measured with a portable HAAKE viscometer.
    [00111] Four samples were run with this printing ink, with increasing line speed: 72.3, 93.8, 113.9 and 134.4 m / min. respectively. The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm.
    [00112] For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the dryer temperature was adjusted to 140 ° C. Samples were collected from all five print runs and
    Petition 870190113726, of 11/06/2019, p. 41/52 / 35 point height and point diameter were measured. The results are detailed in Table 12:
    Table 12
    Sample 23 24 25 26 Line speed (m / min) 72.3 93.8 113.9 134.4 Thickness (mm) 0.81 0.81 0.82 0.82 Point height (mm) 0.25 0.25 0.26 0.26 Spot diameter (mm) 1.0 1.0 1.0 1.0
    [00113] Neither the stitch height nor the stitch diameter are affected by the increasing line speeds. The printing process is stable and can be run at variable speeds as needed.
    Example 12
    Viscosity effect on stitch height and diameter [00114] A 55gsm fabric was manufactured using a blend of standard 40% Viscose and 60% PET matting technology fibers and dots were printed on the finished fabric, but not dried using a screen printer as described above. The ink formulation used for printing consisted of the following ingredients:
    VHA-4: 200 Kg
    NWB Blue: 1.5 Kg
    Water: 5.5 Kg
    AVCOCLEAR 150: 0.4 Kg [00115] This formulation has a solid content of 39.7%. The viscosity of this formulation is 2,100 cP (at 60 rpm).
    [00116] Four samples were run with this printing ink, with increasing printing ink viscosity (achieved by adding increasing amounts of AVCOCLEAR 150) as measured at 60 rpm using a Haake portable viscometer: 2,100, 3,300, 4,500 and 5,500 cP . The base fabric (without printing) has a height of 49.2 gsm and a thickness of 0.56 mm.
    [00117] For printing, a CP30 / 0.50 / 200 screen (manufactured by the Stork Co., Austria) was used, the line speed (print speed)
    Petition 870190113726, of 11/06/2019, p. 42/52 / 35 was set to 72.3 m / min and the dryer temperature was set to 140 ° C. Samples were collected from all four print runs and point height and point diameter were measured. The results are detailed in Table 13:
    Table 13
    Sample 23 24 25 26 Viscosity (cP) 2,100 3,300 4,500 5,500 Thickness (mm) 0.72 0.78 0.80 0.87 Point height (mm) 0.16 0.22 0.24 0.31 Spot diameter (mm) 1.0 1.0 0.8 to 0.9 0.8 to 0.9
    [00118] As noted in Fig. 7, the spot size decreases with increasing viscosity, which can be expected as the wet spot, but printed will flow less into higher viscosity. The stitch height increases with increasing viscosity as the printing ink is less and less capable of penetrating the fabric and the entire inflation effect is directed out of the fabric.
    [00119] All the above description and examples have been provided for the purpose of illustration and are not intended to limit the invention in any way. Many modifications and variations can be provided in the methods, operating conditions and components of the invention, without exceeding the scope of the claims.
    权利要求:
    Claims (10)
    [1]
    1. An in-line process for the manufacture of a non-woven cloth having distributed elements on its surface having a physical dimension, comprising printing on a wet non-woven cloth in a desired way using a thixotropic paste formulation comprising a polymer, a crosslinking, a surface tension modifier and an inflating agent, the process characterized by the fact that the thixotropic printed paste formulation expands under heating due to the inflating agent contained therein.
    [2]
    2. Thixotropic paste suitable for carrying out the online printing process, the process as defined in claim 1, the paste characterized by the fact that it comprises a polymer, a crosslinking agent, a surface tension modifier and an inflating agent.
    [3]
    3. Paste according to claim 2, characterized by the fact that it contains a rheology modifier.
    [4]
    4. Paste according to claim 2, characterized by the fact that it has low shear viscosity, measured with a Brookfield rotary viscometer at a speed of 1 rpm, from 60,000 to 120,000 cP, preferably from 70,000 to 90,000 cP , such as to prevent the material of the formulation which was deposited from draining into both the fabric and the sides, and a high shear viscosity, measured with a Brookfield rotary viscometer at a speed of 100 rpm, less than 2,000 cP, such that allows the transport of ink through the printing unit and distribution to the printer and its movement through the printing screen.
    [5]
    5. Paste according to claim 4, characterized by the fact that it has a medium-shear viscosity, measured with a Brookfield rotary viscometer at 60 rpm, from 1,500 to 5,000 cP, preferably from 2,000 to 4,500 cP.
    Petition 870190113726, of 11/06/2019, p. 44/52
    2/3
    [6]
    6. Paste according to claim 2, characterized by the fact that it contains a total concentration of solid material of 15 to 45% by weight.
    [7]
    7. Paste according to claim 2, characterized by the fact that a defined shape stability for a period of at least 5 minutes during which a drop of 1 cm 3 of paste dripped in 100 ml of water without agitation maintains its integrity .
    [8]
    8. Paste according to claim 2, characterized by the fact that it comprises
    The. Water;
    B. An acrylic copolymer of Styrene, Butyl Acrylate and Acrylonitrile;
    ç. An acrylic copolymer of Styrene, Butyl Acrylate, Ethyl Acrylate and Acrylic acid;
    d. One or more crosslinking agents;
    and. One or more rheology modifiers;
    f. One or more emulsifiers; and
    g. Conventional processing aids, additives and defoaming agents.
    [9]
    9. Paste according to claim 8, characterized by the fact that it comprises, by weight:
    a) 55.0 to 85.0% water
    b) 10.0 to 35.0% of an acrylic copolymer composed of styrene (60 to 70%); butyl Acrylate (25 to 35%); and acrylonitrile (1 to 5%);
    c) 5.0 to 20.0% of an acrylic copolymer composed of styrene (25 to 35%); butyl Acrylate (60 to 70%); ethyl acrylate (1 to 5%); acrylic acid (1 to 5%); d) N-Methylol acrylamide as a cross-linking ingredient (1 to 3%);
    e) 0.2 to 1.0% of an acid ammonium salt thickener
    Petition 870190113726, of 11/06/2019, p. 45/52
    3/3 polyacrylic;
    f) 0.3 to 1.0% Urea;
    g) 0.0 to 0.5% Diethylene Glycol;
    h) 0.1 to 0.5% of polyethoxylated fatty alcohol (C9-C11);
    i) 0.0 to 0.5% of polyethoxylated (C 13) Isotridecanol;
    j) 1.0 to 3.0% of polyethoxylated stearyl alcohol (C16-C18);
    k) 0.5 to 1.5% sodium lauryl sulfate;
    l) 0.0 to 0.5% Polydimethyl Siloxane;
    m) 0.0 to 0.3% Silica;
    n) 0.0 to 0.5% oxidized aliphatic hydrocarbon;
    o) 0.1 to 0.5% sodium benzoate;
    p) 0.0001% Methyl iso-thiazolinone;
    q) 0.0006% Methyl-Chloro-iso-thiazolinone;
    r) 0.1 to 0.75% Trimethylpropane tris-2-methyl-1-aziridinepropionate.
    [10]
    10. Non-woven cloth, characterized by the fact that it comprises elements of exfoliation or abrasives on its surface, which are made of the paste as defined in claim 2.
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    同族专利:
    公开号 | 公开日
    US20120094091A1|2012-04-19|
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    BR112013009052A2|2016-07-19|
    CA2814232C|2015-09-15|
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    IL215735D0|2011-12-29|
    RU2584203C2|2016-05-20|
    RU2013116389A|2014-10-20|
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    US8821979B2|2014-09-02|
    EP2444547B1|2015-08-12|
    CO6710922A2|2013-07-15|
    PL2444547T3|2016-01-29|
    WO2012052991A3|2012-08-02|
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    法律状态:
    2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-08-13| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2019-11-26| B09A| Decision: intention to grant|
    2019-12-17| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/10/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US39440710P| true| 2010-10-19|2010-10-19|
    PCT/IL2011/000811|WO2012052991A2|2010-10-19|2011-10-11|In-line printing process on wet non-woven fabric and products thereof|
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