CA1160010A - Nonwoven fabrics - Google Patents

Nonwoven fabrics

Info

Publication number
CA1160010A
CA1160010A CA000363864A CA363864A CA1160010A CA 1160010 A CA1160010 A CA 1160010A CA 000363864 A CA000363864 A CA 000363864A CA 363864 A CA363864 A CA 363864A CA 1160010 A CA1160010 A CA 1160010A
Authority
CA
Canada
Prior art keywords
fabric
nonwoven fabric
fibers
intertwined
woven fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000363864A
Other languages
French (fr)
Inventor
Shuji Okano
Shigeo Fujii
Tokuzo Ikeda
Takashi Mikami
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tonen General Sekiyu KK
Original Assignee
Toa Nenryo Kogyyo KK
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toa Nenryo Kogyyo KK filed Critical Toa Nenryo Kogyyo KK
Application granted granted Critical
Publication of CA1160010A publication Critical patent/CA1160010A/en
Expired legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
A bulky nonwoven fabric comprises fine fibers per-pendicular to the surface of the fabric, that is, parallel to the direction of thickness of the fabric. The nonwoven fabric of thermoplastic resin is prepared by a melt-blow-ing process utilizing a drum collector and cooperating nip-roll. If desired the fiber and gas stream may be contacted with fine liquid drops.

Description

This invention relates to a novel bulky nonwoven fabric formed by an orderly arrangement of ~ibersO
Many kinds of nonwoven fabrics have hitherto been developed, and are widely used for various applications.
There are, thus, various types of nonwoven fabrics, and various methods of making the sa~e, including those known under the name of the melt blowing method (Japanese Patent Application Laid-Open Specification No. 10258/1974), the melt-blow molding method (Japanese Patent Application Laid-Open Specification No. 46972/1975), the jet spinning method (Japanese Patent Publication No. 25871/1969), or the like. According to these methods, a thermoplastic resin is melt-spun, and blown in the form of fine fibers against a moving collector by a high-speed flow of a gas.
A study has recently come to be made about the use of the nonwoven fabrics obtained by these~methods for making filter materials, carpets, synthetic leathers, or the like.
However, the nonwoven fabrics prepared by any such method lack uniformity in thickness and basis weight, and are not bulky since, the fibers lie parallel to the fabric surfaces (i~e., two-dimensionally). These prior art products present various obstacles to the preparation of satisfactory products as intended, and no satisfactory carpet, leather or the like has yet been prepared from the nonwoven fabrics available in the art.
It is an object of this invention to provide a non-woven fabric having a novel structure which eliminates the drawbacks of the nonwoven fabrics known in the art. This invention consists essentially in a melt blown nonwoven fabric comprising stacked and intertwined long fibers ~orming thin intertwined layers extending between one surface of said fabric or part thereof and another surface of said fabric or part thereof.
In the drawings:
FIGURE 1 is a view schematically showing a nonwoven fabric embodying this invention.
FIGURE 2 is a view similar to FIGURE 1 showing a ~ ~ 6~
-1 nonwoven fabric known in the art;
2 FIGURE 3 is a perspective view generally showing
3 the nonwoven fabric of this invention;
4 FIGVRE 4 to 7 illustrate various forms of the non-woven fabric of this invention at plane A in FIGURE l;
6 FIGURE 8 is a detailed view illustrating a method 7 of manufacturing the nonwoven fabric according to this in-8 vention.
9 FIGURES 9 and 10 are views describing the apertures with which the side wall of the drum 81 supporting the col-11 lector 8 shown in FIGURE 8 is pierced; and 12 FIGURE 11 iS a view describing the process in which 13 the nonwoven fabric is formed by the method shown in FIGURE
14 8.
The nonwoven fabric of this invention will now be 16 described with reference to the drawings. In FIGURE 1, nu-17 merals 2 and 2' denote the opposite surfaces of the nonwoven 18 fabric 1, letter A indicates one cross-sectional plane ex-19 tending between the surface 2 or a part thereof, and the surface 2' or a part thereof (which for the sake of conven-21 ience will hereinafter be called the longitudinal sectional 22 plane), and letter B indicates another cross-sectional plane 23 extending between the surface 2 or a part thereof~ and the 24 surface 2' or a part thereof (which will hereinafter be called the transverse sectional plane)7 Numeral 3 denotes 26 an intermediate fibrous layer disposed between the surfaces 27 2 and 2', and composed of a plurality of long fibers which 28 are intertwined and stacked together. Numerals 4, 4', 4"
29 indicate thin layers each composed of intertwined long fi-bers. The thin layers 4, 4', 4", are actually continuously 31 combined with one another, and cannot be distinquished from 32 one another as clearly as shown in FIGURE 1, which is a 33 schematic view provided for the convenience of illustration.
34 However, as it is possible to divide the fabric into such layers, each having a desired thickness, FIGURE 1 shows the 36 fabric as if it were composed of clearly distinguishable 37 layers.

1 FIGURE 1 shows the thin layers 4, 4', ~", which co-2 operate with one another to define the surfaces ~ and 2' of 3 the nonwoven fabric 1. This feature makes the nonwoven 4 fabric of this invention comp:Letely different from any known nonwoven fabric having such thin layers 104, 104' 104" lying 6 substantially in parallel to its surfaces 102 and 102' as 7 shown in FIGURE 2.
8 The thin layers 4, 4', 4" shown in FIGURE 1 are each 9 formed by a plurality of long fibers intertwined and col-lected on the surfaces. In other words, the thin layers 11 are of the same construction as in the nonwoven fabrics 12 known in the art. Accordingly, the nonwoven fabric of this 13 invention is characterized by the single fibers lying to-14 gether along the thickness of the fabric. The single fibers forming each of the thin layers are intertwined, and con-16 nected to the surfaces 2 and 2' to define them.
17 The structure of the nonwoven fabric according to 18 this invention has been schematically shown in FIGURE 1.
lg FIGURES 3 to 7 show embodiments of the nonwoven fabric of the invention. FIGURES 4 to 7 illustrate the plane A of 21 FIGURE 1. FIGURES 3 to 6 show the surfaces 2 and 2' de~ined 22 by surface layers composed of a multiplicity of fibers;
23 FI~URE 7 shows the surface 2 formed by long fibers exposed 24 from the fibrous layer 3 per se. The nonwoven fabric of the type shown in FIGURE 7 may also be prepared if a nonwoven 26 fabric of the type as shown in FIGURES 3 to 6 is cut along 27 any longitudinal plane lying between the surfaces 2 and 2' 28 in parallel thereto.
29 The nonwoven fabric of this invention constructed as hereinabove described usually has a thickness of about 0.5 31 to about 100 mm, and a basis weight of about 5 to about 32 2,000 g/m2. It is preferably prepared from very fine fibers 33 having a diameter usually in the range of about 0.1 to about 34 30 ~, prefe:rably in the range of about 1 to about 20 ~ and more preferably in the range of about 2 to about 10 ~.
36 Although the nonwoven fabric of this invention can 37 be made of any material without any limitation in particu-V~l~
lar, it is desirable to prepare it from a thermoplastic resin.
Examples of the thermoplastic resin which can be used include polyolefins such as homopolymers of ethylene, propylene, butene-l, 4-methylpentene-1, or other ~-olefins, copolymers thereof, and the mixtures of those polymers, polyamides such as nylon 6, nylon 66, nylon 612, nylon 12 (trade or common names), and their mixtures, polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polyurethane, particularly thermoplastic polyurethane, ethylene~vinyl acetate copolymers, ethylene-methacrylic acid ester copolymers, and graft copolymers of polyolefins with unsaturated carboxylic acids or their derivatives. It is also possible to use any mixture of those thermoplastic resins.
The nonwoven fabric of this invention may be manufac-tured by various melt blown methods. It is possible to prepare the surface layer 2 and the fibrous layer 3 separately, and combine them together, but it is more desirable to form them as an integral assembly in a single stage of operation. A pre-ferred method for making the nonwoven fabric according to this invention will be described hereunder by way of example.
Referring to FIGURE ~ which illustrates a melt blowing process, a thermoplastic substance is fed into an extruder 5 through its hopper 11, and melted under heat in the extruder 5.
The molten substance is fed through a die 6 provided on the extruder 5, and is continuously spun through spinning holes 61 in the die 6. The die 6 is provided on both sides of its spinning holes 61 adjacent thereto with gas emitting ports 62, and gas feeding tubes 63 for supplying a gas into the gas emit-ting ports 62. A high pressure gas supplied through the gas feeding tubes 63 is blown out through the gas emitting ports 62 at a speed which is close to that of sound. The thermoplastic substance spun through the spinning holes 61 is divided into fine fibers by the gas discharged through the gas emitting holes 62 at such a high speed, thereby forming a stream of fibers 7 with the gas. If required, a liquid drop supply-~ - 4 -1 ing unit 10 is provided for supplying liquid drops toward 2 the fiber stream 7. After the fiber stream 7 is contacted 3 with such liquid drops (though such contact is not essen-4 tially required), the fiber stream 7 is blown against a fiber impinging portion P of a collector 8. The collector 6 8 comprises a net or porous plate of a synthetic resin hav-7 ing a mesh size of 5 to 200 mesh, preferably 5 to 100 mesh 8 and more preferably 10 to ~O;mesh, and wound about a hollow 9 cylindrical drum 81. The drum 81 has a cylindrical side wall pierced with a multiplicity of apertures 83. Each of 11 the apertures 83 perferably has an inwardly tapered longi-12 tudinal section, and is defined by an inner portion 84 and 13 an outer portion 85 having a greater diameter than the inner 14 portion 84 as shown in FIGURES 9 and 10. The apertures 83 are circular in cross section. The fibers blown against the 16 surface of the collector 8 are separated from the fiber 17 stream 7, and form a nonwoven fabric 1. The nonwoven fabric 18 thus formed is compressed by a presser 9 into a predeterm-19 ined thickness, and wound about a winder 13 after passing around rolls 71 and 71'. The presser 9 comprises a net or 21 porous plate of the same nature as that of which the col-22 lector 8 is made, which net or plate extends about drums 91 23 and 91' of the same nature with the drum 81. A fiber col 24 lecting zone 12 is defined between the collector 8 and the presser 9. A spray 14 is provided for supplying a cooling 26 fluid to the collector 8, if required.
27 The nonwoven fabric of this invention can be manu-28 factured efficiently by the method as hereinabove described.
29 FIGURE 11 schematically illustrates the process by which the fibers form a fabric. When the fiber stream 7 formed by a 31 plurality of long fibers is blown into the fiber collecting 32 zone 12 defined between the collector 8 and the presser ~, 33 the individual fibers are intertwined and stacked together 34 to form a nonwoven fabric 1~
The longitudinal sectional plane of the nonwoven 36 fabric 1 as shown at A in FIGURE 1 may have various patterns 37 as shown in FIGURES 3 to 7, which depend on the angle at 1 which the fiber stream 7 is blown, and/or the relative posi-2 tion of the collector 8 and the presser 3. More specifi-3 cally, if the fiber stream 7 is blown at a small angle, or 4 if the collector 8 and the presser 9 are spaced a greater distance apart from each other, the thin layers 4, 4', 4"
6 have a tendency to lie genera:L.ly straightly as shown in 7 Figure 4. If, on the contrary, the fiber stream 7 is blown 8 at a large angle, or the collector 8 and the presser 9 are 9 brought closer to each other, the thin layers 4, 4', 4" each have an acutely bent shape as shown in FIGURE 6.
11 The nonwoven fabric of this invention constructed 12 as hereinabove described has a fine hand, and is bulky, and 13 demonstrates excellent results not obtained from any known 14 nonwoven fabric when used for making filter materials, car-pets, substrates for synthetic leathers, or the like.

Claims (6)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A melt blown non-woven fabric consisting essentially of stacked and intertwined long fibers forming thin intertwined layers extending between one surface of said fabric or part thereof and another surface of said fabric or part thereof.
2. A non-woven fabric according to claim 1, wherein the fibers have a diameter of about 0.1 to about 30 microns,
3. A non-woven fabric according to claim 1 having a basis weight of about 5 to 2,000 g/m2.
4. A non-woven fabric according to claim 1 having a thickness of about 0.5 to about 100 mm.
5. A melt blown non-woven fabric consisting essentially of stacked and intertwined long fibers forming thin intertwined layers extending between one surface of said fabric or part thereof and the other surface of said fabric or part thereof, said fibers having a diameter of about 0.1 to 30 microns, said fabric having a basis weight of about 5 to about 2,000 g/m2 and a thickness of about 0.5 to 100 mm.
6. A non-woven fabric according to claim 5 wherein the fibers are connected to one or more surfaces of the fabric.
CA000363864A 1979-11-01 1980-11-03 Nonwoven fabrics Expired CA1160010A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP140,439/79 1979-11-01
JP14043979A JPS5668152A (en) 1979-11-01 1979-11-01 Nonwoven fabric

Publications (1)

Publication Number Publication Date
CA1160010A true CA1160010A (en) 1984-01-10

Family

ID=15268666

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000363864A Expired CA1160010A (en) 1979-11-01 1980-11-03 Nonwoven fabrics

Country Status (7)

Country Link
JP (1) JPS5668152A (en)
BE (1) BE885979A (en)
CA (1) CA1160010A (en)
CH (1) CH650039A5 (en)
DE (1) DE3041089A1 (en)
FR (1) FR2468675A1 (en)
GB (1) GB2063321B (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10704173B2 (en) 2014-01-29 2020-07-07 Biax-Fiberfilm Corporation Process for forming a high loft, nonwoven web exhibiting excellent recovery
US10961644B2 (en) 2014-01-29 2021-03-30 Biax-Fiberfilm Corporation High loft, nonwoven web exhibiting excellent recovery

Families Citing this family (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2611754B1 (en) * 1987-02-27 1989-05-05 Cofpa PROCESS FOR FORMING NONWOVEN WEB OF SYNTHETIC FILAMENTS AND PLASTIC CANVAS FOR APPLYING THIS METHOD
JPH05226569A (en) * 1992-01-08 1993-09-03 Nec Corp Lead frame for resin-sealed semiconductor device use
JP2557511Y2 (en) * 1992-01-16 1997-12-10 セイレイ工業株式会社 Abnormality detection control device of nursery box accumulation device
GB2387180B (en) * 1999-04-30 2003-12-03 Kimberly Clark Co Controlled loft and density nonwoven webs and method for producing
US6588080B1 (en) 1999-04-30 2003-07-08 Kimberly-Clark Worldwide, Inc. Controlled loft and density nonwoven webs and method for producing
US7476632B2 (en) * 2002-11-15 2009-01-13 3M Innovative Properties Company Fibrous nonwoven web
DE10311439A1 (en) * 2003-03-15 2004-09-23 Saurer Gmbh & Co. Kg Assembly to spin and lay bands of melt spun filaments, for the production of nonwovens, has a filament take-off and spaced guide rollers with continuous belt extensions, to gather the filaments on a sieve laying surface
CN100537860C (en) 2003-04-03 2009-09-09 纳幕尔杜邦公司 Form the method for uniformly distributed material
GB2427357A (en) * 2005-06-22 2006-12-27 Bandvulc Tyres Ltd Carpet underlay
CN104246045B (en) 2012-04-27 2016-11-02 欧瑞康纺织有限及两合公司 For limited fibre meltblown, shaping and lay are become the method and apparatus of fiber matting
US20150211160A1 (en) * 2014-01-29 2015-07-30 Biax-Fiberfilm High loft, nonwoven web exhibiting excellent recovery
EP3425099A1 (en) * 2017-07-03 2019-01-09 Axel Nickel Meltblown non-woven fabric with improved stackability and storage
JP7089358B2 (en) * 2017-11-28 2022-06-22 日東電工株式会社 Porous fiber sheet
JP7097781B2 (en) 2018-08-23 2022-07-08 日東電工株式会社 Laminated sheet
JP7419637B2 (en) * 2019-10-15 2024-01-23 日本ノズル株式会社 Melt-blown nonwoven fabric and its manufacturing method

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AT207674B (en) * 1959-01-14 1960-02-25 Otto Dr Angleitner Textile nonwoven and process and device for its manufacture
DE1485529A1 (en) * 1962-08-06 1969-06-26 Freudenberg Carl Fa Process for the production of fiber mats
US3738884A (en) * 1966-09-21 1973-06-12 Celanese Corp Method for producing non-woven fibrous products
US3740302A (en) * 1966-09-21 1973-06-19 Celanese Corp Spray spun nonwoven sheets
US3607588A (en) * 1966-09-21 1971-09-21 Celanese Corp Nonwoven fibrous products and methods and apparatus for producing such products
FR1541618A (en) * 1967-09-29 1968-10-04 Celanese Corp Process and installation for the manufacture of non-woven fibrous products and products thereof
US3676239A (en) * 1970-12-08 1972-07-11 Celanese Corp Method of producing spray spun nonwoven sheets
US3819452A (en) * 1970-12-08 1974-06-25 Celanese Corp Apparatus for the production of spray spun nonwoven sheets
US4100324A (en) * 1974-03-26 1978-07-11 Kimberly-Clark Corporation Nonwoven fabric and method of producing same
JPS6056825B2 (en) * 1978-05-01 1985-12-12 東亜燃料工業株式会社 Manufacturing method of nonwoven fabric
JPS6022100B2 (en) * 1978-05-01 1985-05-31 東亜燃料工業株式会社 Manufacturing method of nonwoven fabric

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10704173B2 (en) 2014-01-29 2020-07-07 Biax-Fiberfilm Corporation Process for forming a high loft, nonwoven web exhibiting excellent recovery
US10961644B2 (en) 2014-01-29 2021-03-30 Biax-Fiberfilm Corporation High loft, nonwoven web exhibiting excellent recovery

Also Published As

Publication number Publication date
FR2468675B1 (en) 1985-03-01
JPS5668152A (en) 1981-06-08
DE3041089A1 (en) 1981-05-21
GB2063321B (en) 1984-05-31
FR2468675A1 (en) 1981-05-08
BE885979A (en) 1981-04-30
GB2063321A (en) 1981-06-03
JPS6410618B2 (en) 1989-02-22
CH650039A5 (en) 1985-06-28

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