Title:
Fabric with a base of non-woven fabric strips
Kind Code:
A1


Abstract:
A textile product is described which is composed of a weft and a warp, in which the weft and/or the warp are composed of strips of non-woven fabric. This product is applied in the production of cloths for cleaning floors, dusters, napkins, bedspreads, couch covers, cushion covers, car seat covers, doormats, etc. The strips of non-woven fabric are preferably composed of hydroentangled or thermobonded fibres, and with a base of materials such as viscose, polyethylene, polypropylene, polyamide, cellulose pulp. The invention also includes mixed textile products, in which non-woven products are combined with materials other than non-woven such as wool, silk, synthetic fibres, etc. This method is advantageously, though not exclusively, suited for recycling even waste materials derived from the processing of non-woven fabric.



Inventors:
Orlandi, Vittorio (Arsago Seprio, IT)
Application Number:
10/537842
Publication Date:
02/16/2006
Filing Date:
12/01/2003
Primary Class:
Other Classes:
139/420R
International Classes:
D03D15/00
View Patent Images:
Related US Applications:
20070042661Mineral fibre-based insulating panel, production method thereof and use of sameFebruary, 2007Ferri et al.
20100035500STRETCHABLE NONWOVEN FABRIC AND TAPEFebruary, 2010Kimura et al.
20010018305Polyester fabric and process for the preparation thereofAugust, 2001Habereder et al.
20080045104Flameproof Artificial LeatherFebruary, 2008Sugiyama et al.
20100003881METHODS AND APPARATUS ASSOCIATED WITH NARROW TOWS FABRICATED FROM LARGE-TOW PREFORMSJanuary, 2010Tsotsis
20050281976Looped nonwoven webDecember, 2005Curro et al.
20050136757Press felt with regenerated cellulosic scrimJune, 2005Despault et al.
20030064649Sound absorbing material and interior material using the sameApril, 2003Miura et al.
20060019569Sound absorbing composite materialJanuary, 2006Lin
20060030226Non-ceramic hard armor compositeFebruary, 2006Park et al.
20040242096Net reinforced compositeDecember, 2004Prakash



Primary Examiner:
JOHNSON, JENNA LEIGH
Attorney, Agent or Firm:
Jay S Cinamon (New York, NY, US)
Claims:
1. Textile product composed of a weft and a warp, in which the weft and/or the warp are composed of strips of non-woven fabric.

2. Textile product according to claim 1, wherein the non-woven fabric is composed of hydroentangled, thermo-bonded or span-bonded fibres.

3. Textile product according to claim 1, wherein the non-woven fabric is composed of a material chosen from viscose, polyethylene, polypropylene, polyamide, cellulose pulp.

4. Textile product according to claim 1, wherein the non-woven fabric has a weight/surface ratio between 10 g/m2 and 200 g/m2.

5. Textile product according to claim 4, wherein the non-woven fabric has a weight/surface ratio of between 50 g/m2 and 65 g/m2.

6. Textile product according to claims 1, wherein both the weft and the warp are composed of strips of non-woven fabric.

7. Textile product according to claim 1, wherein the weft or the warp is composed of strips of a material other than non-woven.

8. Textile product according to claim 7, wherein said material other than non-woven is chosen from yarns, paper, synthetic fibres.

9. Textile product according to claim 7, wherein said strips of non-woven fabric and/or said strips of material other than non-woven have a width between 1 and 10 cm.

10. Textile product according to claim 9, wherein said strips of non-woven fabric and/or said strips of material other than non-woven have a width between 4 cm and 7 cm.

11. Textile product according to claim 1, wherein said strips of non-woven fabric are obtained from processing waste.

12. Procedure for the preparation of the textile product described in claim 1, characterised in that the strips of non-woven fabric are subjected to weaving, realising a fabric in which the weft and/or the warp are composed of said strips of non-woven fabric.

13. Manufacture realised with the textile product described in claim 1.

14. Manufacture according to claim 13, selected from the group consisting of a cloth for cleaning floors, a duster or cloth for cleaning small surfaces in the home, tablecloth, napkin, matting, mat, mattress cover, bedspread, couch cover, cushion cover, car seat cover, and doormat.

15. Method for the recovery of trimmings from the processing of non-woven fabric, characterised in that said trimmings are interwoven to form a textile material, of which the trimmings of non-woven fabric constitute the weft, the warp or both.

Description:

FIELD OF THE INVENTION

The present invention concerns the field of articles in non-woven fabric, with particular application in the field of cleaning and/or protection of surfaces in the home.

PRIOR ART

Materials with a non-woven base are widely applied in various sectors. In the procedures for producing articles with a non-woven base, this product is normally unwound from bobbins which hold it and processed by means of the treatments required by the article concerned (for example stitching, rolling, incision of patterns in relief, moulding, cutting into the final shape, etc.); collateral with these procedures it the production of high quantities of waste non-woven fabric, composed of the trimmings left over from cutting the fabric into the desired dimensions and shape. Most of these trimmings are in the form of strips of various length, derived from lengthwise cutting of the peripheral portions of non-woven fabric unwound from the bobbin.

These materials are normally discarded or recycled in the production of low-value products. The products of recycling thus obtained do not cover the value of the original material lost in the waste: it is therefore desirable to reduce the waste of material in these procedures, or to increase the economic yield of the recycling of waste, so as to reduce the overall cost of the procedures for producing articles in non-woven fabric.

SUMMARY

The object of the present invention is a method for increasing the economic yield of the recycling of waste from the processing of non-woven fabric. This result has been obtained by applying the techniques of weaving to non-woven fabrics, that is those materials which on account of their nature do not require any weaving. Using this method it has been possible to obtain textile products composed of strips of non-woven fabric interwoven like weft and warp. The products thus obtained, intended for the cleaning and protection of various surfaces, for example in the home, have performances equal to or superior to those of traditional products with a base of textile fibres.

DETAILED DESCRIPTION OF THE INVENTION

The object of the present invention is a textile product composed of a weft and a warp, in which the weft and/or the warp are composed of strips of non-woven fabric.

It has in fact been observed that strips of non-woven fabric, such as those obtained from production trimmings, can be used in the same way as textile products on a loom and interwoven in the form of a weft and warp, thus obtaining a fabric with a base of non-woven fibres.

The resulting textile product has proved to be a high-strength product with considerable versatility of application: in particular the best application of the fabric is in the field of cleaning or protection of various surfaces. It can therefore be used in the manufacture of cloths for cleaning floors, of cloths for cleaning small surfaces in the home (e.g. bathroom, kitchen, etc.), tablecloths, napkins, matting, mats, bedspreads, couch covers, cushion covers, car seat covers, doormats. All the manufacts obtained with the textile product concerned are also part of the present invention.

The strips of non-woven fabric used in the present invention are preferably composed of hydroentangled, thermo-bonded or span-bonded fibres. Examples of materials that constitute non-woven fibres are: viscose, polyethylene, polypropylene, polyamide, cellulose pulp.

For the above applications in the field of cleaning and protecting surfaces, the non-woven fabric used has a weight/surface ratio between 10 g/m2 and 200 g/m2, preferably between 50 g/m2 and 65 g/m2.

In one embodiment of the invention, both the weft and the warp of the textile product concerned are composed of strips of non-woven fabric: this process results in products with considerable uniformity. However, the present invention also comprises materials in which the weft is composed of non-woven fibres and the warp of materials other than non-woven, or vice-versa. In this case materials with different characteristics, which give a different texture, are interwoven, thus allowing an increased grip between fabric and user, and between the fabric and the surface to be cleaned/protected.

The material other than non-woven fabric may be chosen from various yams (for example wool, silk, synthetic fibres such as nylon) or it may be non-yam, such as paper. In particular it has been observed that paper strips can be efficiently interwoven with non-woven fabric, thus obtaining a textile product of high quality and strength.

The strips of which the present textile product are made, be they of non-woven or other material, have a width generally between 1 and 10 cm, preferably between 4 and 7 cm.

As indicated above, the non-woven strips may be a sub-product obtained from processing waste, typically represented by strips of trimmings of non-woven fabric unwound from bobbins or reels. This method is therefore excellent for recycling these materials, obtaining a material with high added value and thus fully recovering the value of the material discarded during the processes for the production of articles in non-woven fabric.

Part of the invention is therefore a method for the recovery of trimmings from the processing of non-woven fabric, characterised in that said trimmings are interwoven to form a textile material, of which the non-woven trimmings constitute the weft, the warp or both.

Although this invention is advantageously suitable for the recovery of processing trimmings, it is nevertheless not to be understood as limited to the use of that raw material. It is in fact also possible, and is part of the present invention, to realise made-do-measure strips having the desired shape, dimensions and weight, and to interweave them together in the form of a weft and warp, in order to obtain products with particular characteristics. It is clear that in this case, thanks to the constant and controlled dimensions of the strips used, the product will present greater uniformity and constancy of characteristics in comparison with a product obtained from recycling strips, which are generally more variable in shape, dimensions and weight.

In a non limiting example of an embodiment of the present invention, selvedges (trimmings) of 4-5 cm were used, with a weight of 50-55 g/cm2; the selvedges were fed into a loom for weaving special products (with high teething), at the speed of 1 m/h, obtaining a web with a height of 160 cm and a roll with a diameter of 50 cm; cloths were made with dimensions 40 cm×50 cm with absorbent capacities equivalent to those of products (polyester viscose) used on the market. The strength in both CD (cross direction) and MD (machine direction) was considerably increased (about 3 times that of standard products). The cloth presented considerable duration and resistance in time after being used to clean floors.