SUPER ABSORBER POLYMER FELT AND METHOD FOR THE PRODUCTION THEREOF

• US 20120036733A1
• Filed: 12/18/2009
• Published: 02/16/2012
• Est. Priority Date: 12/19/2008
• Status: Active Grant

• Current Assignee: IQTEX Patentverwaltung UG
• Original Assignee: IQTEX Patentverwaltung UG
• Inventors: Dehn, Michael Christian
• Granted Patent: US 8,844,158 B2
• Time in Patent Office: Days
• US Class Current: 34/282
• CPC Class Codes: A61F 13/01008 characterised by the material
• CPC Class Codes: A61F 13/01029 made of multiple layers
• CPC Class Codes: A61F 13/01046 Air-vapor permeability
• CPC Class Codes: A61F 13/15658 Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
• CPC Class Codes: A61F 13/535 inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes A61F13/5323, A61F13/537 take precedence
• CPC Class Codes: A61F 13/53704 the layer having an inhibiting function on liquid propagation
• CPC Class Codes: A61F 13/53713 the layer having a promotional function on liquid propagation in the vertical direction
• CPC Class Codes: A61F 13/53717 the layer having a promotional function on liquid propagation in the horizontal direction
• CPC Class Codes: A61F 13/53747 the layer is facing the topsheet layer is part of the topsheet A61F13/511
• CPC Class Codes: A61F 13/53756 the layer facing the back-sheet
• CPC Class Codes: A61F 13/538 characterised by specific fibre orientation or weave
• CPC Class Codes: A61F 13/539 characterised by the connection of the absorbent layers with each other or with the outer layers
• CPC Class Codes: A61F 2013/00246 in a special way pervious to air or vapours
• CPC Class Codes: A61F 2013/00544 form or structure
• CPC Class Codes: A61F 2013/00744 containing non-woven
• CPC Class Codes: A61F 2013/00748 with hydrocolloids or superabsorbers
• CPC Class Codes: A61F 2013/530532 the maximum being at certain depth in the thickness
• CPC Class Codes: A61F 2013/530547 positioned in a separate layer or layers
• CPC Class Codes: A61F 2013/530554 and being fixed to a web
• CPC Class Codes: A61L 15/60 Liquid-swellable gel-forming materials, e.g. super-absorbents
• CPC Class Codes: B32B 2250/03 : 3 layers
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/06 : Vegetal fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/08 : Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: B32B 2262/12 : Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/7163 : Biodegradable
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/722 : Non-uniform density
• CPC Class Codes: B32B 2307/724 : Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2439/00 : Containers; Receptacles
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2581/00 : Seals; Sealing equipment; Gaskets
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/407 : containing absorbing substances, e.g. activated carbon
• CPC Class Codes: D04H 1/413 : containing granules other than absorbent substances
• CPC Class Codes: D04H 1/42 : characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
• CPC Class Codes: D04H 1/4374 : using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/498 : entanglement of layered webs
• CPC Class Codes: D04H 13/00 : Other non-woven fabrics
• CPC Class Codes: Y10T 428/15 : Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24033 : including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24785 : including layer embodying mechanically interengaged strands, strand portions or strand-like strips [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 442/50 : FELT FABRIC
• CPC Class Codes: Y10T 442/51 : From natural organic fiber [e.g., wool, etc.]
• CPC Class Codes: Y10T 442/56 : From synthetic organic fiber
• CPC Class Codes: Y10T 442/57 : Including particulate material other than fiber
• CPC Class Codes: Y10T 442/59 : At least three layers
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition

Abstract

The invention relates to a felt material comprising at least one felt layer and an absorbing layer, to a method for producing the felt material, and to the use of the felt material in textiles, shoes, technical application or medical applications. The felt material according to the invention has the advantages of conventional felt materials regarding the warming and damping properties and is permeable to air in the dry state. Due to the special design, however, it is waterproof in the wet state and thus it is suitable for sealing many materials. The felt material according to the invention binds more humidity or binds water in a different way than common felt materials.

Claims

1. Felt material having a blocking function for climatic regulation, comprising at least one felt layer and at least one fluid absorbing layer deployed at least in partial areas, characterized in that

at least one fluid absorbing layer is an absorber-containing layer,

at least one felt layer and the absorber-containing layer are mutually needled to each other,

the absorber is limited in its three-dimensional expansion by the felt layer(s) and/or by locking elements,

the felt material is at least partial permeable to air in the dry, open state, and

the felt material is closed when it comes into contact with a fluid, water or water vapor with the extension of the absorber, wherein the fluid transport through the felt material is limited or stopped by the swollen absorber.

2. Felt material according to claim 1, characterized in that the absorber layer is an absorber nonwoven material, an absorber polymer, an absorber, an absorber with a carrier material, an absorber granulate, an AirLaid material provided with absorbers, tissue or tissue-like material or absorber fibers.

3. The felt material according to claim 2, wherein the absorber nonwoven material is a nonwoven material with absorber polymers.

4. The felt material according to claim 1, characterized in that the absorber is

a superabsorber polymer, or

a swellable polymer selected from the group consisting of polyacrylic acid, polyacrylic acid copolymers, crosslinked sodium polyacrylate, casein, egg white and thermostatic elastomer composites, or

a superabsorber polymer fiber.

5. The felt material according to claim 1, characterized in that the felt material comprises at least in some areas three layers, wherein the first layer is a felt layer which has a layer made of absorber material arranged thereupon at least in partial areas, and another second felt layer arranged thereupon, while the three layers are at least partially mutually felted/needled with each other.

6. The felt material according to claim 1, characterized in that the absorber is limited in its three-dimensional extension at least partially by the connecting fibers between the felt layer(s).

7. The felt material according to claim 1, characterized in that the felt layer is made of synthetic, semi-synthetic, animal, mineral, metallic, vegetable, biodegradable fibers, hybrid fibers, rubber fibers or a mixture thereof.

8. The felt material according to claim 7, characterized in that the felt layer in addition to functional fibers contains or is mixed with a functional material.

9. The felt material according to claim 8, wherein the functional material is a phase change material (PCM)) or a shape memory material.

10. The felt material according to claim 5, characterized in that the first and the second felt layer are made of the same material, or that the second felt layers are made of different materials.

11. The felt material according to claim 5 characterized in that at least one felt layer and the absorber-containing layer and/or a second felt layer are needled with each other such that the felt material is permeable to air in the dry state and permeable to air and non-permeable to water in the wet state.

12. The felt material according to claim 1, characterized in that the absorber-containing layer is constructed at least partially from fibers soluble in water or soluble in a detergent, or equipped with substances that are soluble in water or in a solvent, which are connected with the absorber polymer or which enclose the absorber polymer.

13. The felt material according to claim 5, characterized in that a covering layer is arranged on the first and/or potentially on the second felt layer, and that the second layer is potentially treated with a surface treatment.

14. The felt according to claim 13, characterized in that the covering layer is provided with perforations or openings, apertures, surface structures, tunnel structures, depressions, designated creasing locations or designated breaking locations and/or separating locations.

15. The felt according to claim 1, characterized in that the felt is provided with fragrances, dyes and/or active ingredients.

16. The felt according to claim 1, characterized in that the felt material additionally contains

molded parts, preferably parts molded from plastic or felt, which are felted with at least one felt layer or felted in the felt material and/or

locking elements, injected through the structure in advance in the direction of the connecting fibers,

17. The felt material according to claim 1, characterized in that in the felt material has a top side and a bottom side, wherein the top side and the bottom side have different properties.

18. Method for manufacturing a felt material comprising at least one felt layer and at least partially at least one absorber-containing layer, characterized in that

at least one absorber-containing layer is placed on one felt layer or between a first and second felt layers, and

the felt layer(s) and the absorber-containing layer are mutually needled with each other, or

one layer provided with precursors of the absorber polymer is placed on the felt layer and between two felt layer, and

the felt layers and precursor-containing layer and/or the second felt layer are mutually needled to each other and the polymerization to absorber polymer is ended during or after the felting procedure, wherein the absorber is swollen when it comes into contact with a fluid, water or water vapor.

19. The method according to claim 18, characterized in that the absorber-containing layer is an absorber nonwoven fabric.

20. The method according to claim 18, characterized in that the absorber-containing layer is constructed from fibers which are soluble in water or in a detergent and which are connected with the absorber polymer or which enclose the absorber polymer.

21. The method according to claim 18, characterized in that the absorber is

a superpolymer absorber, or

a polymer capable of swelling, selected from the group consisting of polyacrylic acid, polyacrylic acid copolymers, crosslinked sodium polyacrylate, casein, egg white and thermostatic elastomer composites, or

a superabsorber polymer fiber.

22. The method according to claim 18, characterized in that the felt layer is made of synthetic, semi-synthetic, animal, mineral, metallic, vegetable, biodegradable fiber, rubber fibers hybrid fibers or a mixture thereof and/or the first and the second felt layer are made of the same material or different materials.

23. The method according to claim 18, characterized in that after needling, a covering layer is applied at least partially to the first and/or second layer and optionally, the covering layer is provided with perforations and openings when it is being applied or after the application.

24. The method according to claim 18, which further comprises a wet felting process step.

25. The method according to claim 18, characterized in that hollow needles are employed at least partially during the needling and felting process, through which the substances can be introduced during the felting process.

26. The method according to claim 18, characterized in that the felt material is provided at least partially with a surface treatment.

27. The method according to claim 18, characterized in that the absorber-containing layer is swollen or partially swollen before it is placed on the felt layer and that it is overfelted in the swollen or partially swollen state.

28. The method according to claim 18, characterized in that molded parts are positioned on the felt layer and or the absorber-containing layer which are felted during the needling with at least one of the layers.

29. The method according to claim 18, characterized in that plastic material is injected through the felt material in order to produce locking elements

30. The method according to claim 29, characterized in that plastic material is injected through the felt material in order to produce locking elements in the direction of the connecting fibers.

31. The method according to claim 18, characterized in that the felt material produced thereby has a blocking function for climatic regulation, comprising at least one felt layer and at least one fluid absorbing layer deployed at least in partial areas, characterized in that

at least one fluid absorbing layer is an absorber-containing layer,

at least one felt layer and the absorber-containing layer are mutually needled to each other,

the absorber is limited in its three-dimensional expansion by the felt layer(s) and/or by locking elements,

the felt material is at least partial permeable to air in the dry, open state, and

the felt material is closed when it comes into contact with a fluid, water or water vapor with the extension of the absorber, wherein the fluid transport through the felt material is limited or stopped by the swollen absorber.

32. Structural component comprising a felt material having a blocking function for climatic regulation, comprising at least one felt layer and at least one fluid absorbing layer deployed at least in partial areas, characterized in that

at least one fluid absorbing layer is an absorber-containing layer,

at least one felt layer and the absorber-containing layer are mutually needled to each other,

the absorber is limited in its three-dimensional expansion by the felt layer(s) and/or by locking elements,

the felt material is at least partial permeable to air in the dry, open state, and

the felt material is closed when it comes into contact with a fluid, water or water vapor with the extension of the absorber, wherein the fluid transport through the felt material is limited or stopped by the swollen absorber.

33. The structural component according to claim 32, characterized in it is equipped with an edge seal.

34. Method for ventilating, dehumidifying, humidifying, sealing and/or climatic regulation of textile or non-textile objects, comprising the step of applying a felt material having a blocking function for climatic regulation, which felt material comprises at least one felt layer and at least one fluid absorbing layer deployed at least in partial areas, characterized in that

at least one fluid absorbing layer is an absorber-containing layer,

at least one felt layer and the absorber-containing layer are mutually needled to each other,

the absorber is limited in its three-dimensional expansion by the felt layer(s) and/or by locking elements,

the felt material is at least partial permeable to air in the dry, open state, and

the felt material is closed when it comes into contact with a fluid, water or water vapor with the extension of the absorber, wherein the fluid transport through the felt material is limited or stopped by the swollen absorber.

35. The method according to claim 34, wherein the felt material is formed as a component in a ventilation insert or ventilation surface and/or dehumidification insert or humidification insert adapted for textiles, clothing, shoes, inner soles of shoes, insert soles, lining, cushion materials, coverings, blankets, covers, tents, safety helmets, protective suits, protective covers, bandages, orthopedic articles, prostheses, containers, housings or bundles.

36. The method according to claim 34, wherein the felt material is formed as a component in a technical filter, seal, sealing tape, absorbent pad, sponge, bandage material, container for condensation water or for a cleaning device.

37. The method according to claim 34, wherein the felt material is formed as a component in a seal, ring seal, O-ring, washer, dehumidification insert in clothing, packaging or housings or structural component of housings.