Process for abrasion-resistant needle-punched composite

Details Process for abrasion-resistant needle-punched composite Process for abrasion-resistant needle-punched composite

D - Textiles, Paper

04

H

D04H 11/08 (2006.01)

Patent

CA 2629625

A process for making abrasion-resistant composites is disclosed. The process comprises the steps of providing a fibrous sheet containing a high density of relatively short staple fibers having a decitex under 6.6; needle-punching the staple layer and applying an adhesive containing layer; followed by the application of heat and pressure to the composite to form a thin consolidated and abrasion-resistant back-face layer on the composite. Preferably, the adhesive layer is penetrated by the needled fibers during the needling step and the product is shrunk in area by 20-50% before the consolidation step. Also optionally, the consolidated layer is abraded or perforated to create micro-pores that are permeable to gases and capable of containing liquids under low-to-moderate pressures.

L'invention concerne un procédé permettant de fabriquer des composites résistant à l'abrasion, qui consiste à fournir une feuille fibreuse contenant une densité élevée de fibres discontinues relativement courtes ayant un décitex inférieur à 6,6; à aiguilleter la couche discontinue et à appliquer une couche adhésive; puis à appliquer chaleur et pression au composite de façon à former sur celui-ci une couche support résistant à l'abrasion et consolidée. De préférence, les fibres aiguilletées pénètrent dans la couche adhésive lors de l'aiguilletage et la surface du produit se rétracte de 20-50 % avant consolidation. La couche consolidée est en outre éventuellement abrasée ou perforée de façon à créer des micropores perméables aux gaz et pouvant contenir des liquides sous des pressions faibles à modérées.

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