Fiber sheet with heat-treated surface layer

• US 20040071947A1
• Filed: 06/04/2003
• Published: 04/15/2004
• Est. Priority Date: 10/12/2002
• Status: Abandoned Application

• Current Assignee: SK Chemicals Co Ltd (SK Discovery Co. Ltd.)
• Original Assignee: SK Chemicals Co Ltd (SK Discovery Co. Ltd.)
• Inventors: Lee, Jun, Hwang, Sung-Su, Jeong, Myong-Guk, Jung, Sang-Min, Shim, Sung-Young
• Application Number:
  US10/453,725
• Publication Number:
  US 20040071947A1
• Time in Patent Office: Days
• US Class Current: 428/292.1
• CPC Class Codes: D04H 1/435 Polyesters
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43832 side-by-side
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/5412 sheath-core
• CPC Class Codes: D04H 1/5414 side-by-side
• CPC Class Codes: D04H 1/5418 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/55 Polyesters
• CPC Class Codes: D04H 1/559 the fibres being within layered webs
• CPC Class Codes: D04H 1/60 the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
• CPC Class Codes: D04H 1/74 the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• CPC Class Codes: D06C 15/02 between co-operating press or calender rolls
• CPC Class Codes: E04B 1/8409 sheet-shaped
• CPC Class Codes: G10K 11/162 Selection of materials
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

Disclosed is a fiber sheet having a heat-treated surface layer, comprising a polyester fiber applicable as heat insulating and sound absorbing materials. The fiber sheet is prepared by forming a surface layer at a particular level by continuously heat-treating a surface of the fiber sheet using 1 to 3 sets of hot press rollers at a post-process, where one set of the rollers consists of two rollers vertically arranged. Compared to the conventional products, the fiber sheet of the present invention has improved desurfacing property and bending strength, and good workability and interior property, as well as having improved texture, sound absorbing property and moisture resistance by regulating the size of surface pores.

Claims

1. A fiber sheet having a heat-treated surface layer, formed on a surface of the fiber sheet by compression using a hot press roller set to a temperature of 150-250°

C. and having an average pore size of less than 500 μ

m, wherein the fiber sheet comprises a polyester binder fiber wholly or partially including a low melting point polyester having a melting point of 80-120°

C., and a polyester matrix fiber having a melting point relatively higher than that of the low melting point polyester.

2. The fiber sheet as set forth in claim 1, wherein the average pore size of the heat-treated surface layer is from 50 to 500 μ

m.

3. The fiber sheet as set forth in claim 1, wherein the average pore size of the heat-treated surface layer is from 100 to 400 μ

m.

4. A method of preparing a fiber sheet having a heat-treated surface layer, comprising:

preparing a fiber sheet by mixing and carding a polyester binder fiber wholly or partially including a low melting point polyester having a melting point of 80-120°

C., and a polyester matrix fiber having a melting point relatively higher than that of the low melting point polyester, layering the resulting webs, and heat-bonding the layered webs at a temperature higher than the melting point of the low melting point polyester and lower than that of the polyester matrix fiber;

cooling the heat-bonded fiber sheet; and

compressing one or both surfaces of the cooled fiber sheet using a hot press roller set to 150-250°

C. to form a heat-treated surface layer having an average pore size of less than 500 μ

m.