CA1237884A - Apparatus for producing a patterned belt bonded material - Google Patents

Apparatus for producing a patterned belt bonded material

Info

Publication number
CA1237884A
CA1237884A CA000521281A CA521281A CA1237884A CA 1237884 A CA1237884 A CA 1237884A CA 000521281 A CA000521281 A CA 000521281A CA 521281 A CA521281 A CA 521281A CA 1237884 A CA1237884 A CA 1237884A
Authority
CA
Canada
Prior art keywords
belt
web
open mesh
fabric
causing
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
CA000521281A
Other languages
French (fr)
Inventor
Alfred T. Mays
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.)
Chicopee Inc
Original Assignee
Chicopee Inc
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
Priority claimed from CA000437830A external-priority patent/CA1226486A/en
Application filed by Chicopee Inc filed Critical Chicopee Inc
Priority to CA000521281A priority Critical patent/CA1237884A/en
Application granted granted Critical
Publication of CA1237884A publication Critical patent/CA1237884A/en
Expired legal-status Critical Current

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  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)

Abstract

ABSTRACT
APPARATUS FOR PRODUCING A PATTERNED BELT
BONDED MATERIAL
An apparatus for heat fusing low shrink tunnel plastic fibers in a nonwoven web. The apparatus comprises a heating apparatus and a first endless carrier belt which travels in a curvilinear path adjacent the heating device. An open mesh belt having an open mesh of up to 6.8 mesh/inch travels along the initial path spaced from the first belt and then along the curvilinear path.

Description

8'~

~his applic~tion is a divisional application of Application Serial Number 437,830 filed September 28, 1983.
Patterned Belt Bonded Material and Method for MaXinq the Same Backqround of the_Invention Honeycomb currently markets an apparatus for heating and fusing thermoplastic fibers in a web. The appa-ratus is a modification of their thru~air bonder for drying and heat setting fibrous webs~ In this appa-ratus, the web is carried about a rotating drum and heated air is blown onto the web. When starting with a high loft, low density web, such an apparatus yields a very high loft, low density fabric having limited strength. There is known an apparatus and method wherein the web is carried about an open mesh struc-ture which i-s substituted for the surface of the drum.
This apparatus and method produces a unique fabric having patterned regions of even higher loft where fibers are bent out of the plane of the fabric. An-other method and apparatus for heat fusing thermo-plastic fibers is known and wherein, the web is picked up by a first carrier belt, a second carrier belt is placed on top of the web and the double belt laminate is passed about heated rolls. A fabric made by the double belt bonder has good strength including good cross directional strength but is more dense and not as lofty as fabric made on the Honeycomb apparatus.
Summary of the Invention The present invention comprises a method and apparatus - for forming a fabric from a web comprising at least five percent low shrink thermoplastic fibers includ-ing conjugate fibers and the fabric formed thereby.The method comprises heating a web comprising said low shrink thermoplastic fibers to heat fuse the fibers in the web while ~r,~
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the web is tensioned between a first carrier belt and an open mesh belt. When conj~gate fibers are used, the method comprises fusing at least the low melting point component of the conjugate fibers. The apparatus of the present invention comprises heating means, a first carrier belt and means for causing said belt to travel in an arc~-ate path adjacent the heating means, an open mesh belt and means for causing said open mesh belt to travel along an initial path spaced from said first carrier belt and then along said arcuate path. The fabric formed by the method and apparatus of the present invention has a surface pat-tern on at least one surface thereof and patterned densi-fied regions which are created by the open mesh belt. The fabric has high loft and low density as well as good ~5 strength. The open mesh belt may be overlaid-by a second carrier belt sandwiching the web and open mesh belt between two carrier belts. The first carrier belt may comprise a second open mesh belt to form a fabric with a pattern on both surfaces. The strength, cushioning, and absorbency of the fabric make it attractive for many end uses including as a diaper facing material. I~hen used as a diaper facing, the fabric ~ay comprise hydrophobic fibers. When only one surface of the fabric is patterned, the fabric displays a greater porosity on the patterned side and a lesser porosity on the unpatterned side providing enhanced wicking from the patterned surface and minimize strike back when used as, for example, a diaper facing.

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- 2a -According to a further broad aspect of the present invention, there is provided an apparatus for using low shrink thermoplastic fibers in a nonwoven web. The apparatus comprises heating means, first endless carrier belt and means for causing the first endless carrier belt to travel in a curvilinear path adjacent the heating means. An open mesh belt is also provided and further means for causing the open mesh belt, of up to 6.8 mesh/inch to travel along an initial path spaced from the first belt and then along the curvilinear path.
Brief ~escription of the Drawings Figure 1 is a schematic side view of one embodiment of the apparatus and method to the present invention.

Figure 2 is a plan view of a portion of the open mesh belt for use according to the present invention ~i~37~4 Figure 3 is a perspective view of one embodiment of a fabric according to the present invention.

Eigure 3A is a fragmentary section of the fabric of Figure 3 illustrating schematically how the fabric was formed.

Figure 4 is a perspective view of another embodiment of a fabric according to the present invention.

Figure 4A is a fragmentary section of the fabric of Figure 4 illustrating schematically how the fabric was formed.

Description of the Drawings The present invention comprises an apparatus and a method for making a fabric from a web comprising low shrink thermoplastic fibers, including conjugate fibers and the fabric formed thereby. It is preferred to employ sheath/
core conjugate fibers of polyethylene/polyester respec-tively. Sheath/core fibers of polyethylene/polypropylenemay also be used, as well as low shrink thermoplastic such as Eastman 4BC crystalline copolyester monofil. Either eccentric or concentric sheath/core fibers can be employed.
Figure 1 illustrates, schematically, a side view of one embodiment of the apparatus of the present invention wllerein the heating means comprises heated rolls or steam cans. Alternate heating means, such as a ~ioneycomb apparatus, may be used, including any other heating means where the belts can travel in tensioned arcuate paths adjacent the heating means.

In the method shown, a first endless carrier belt 3, is provided having means 5, for causing said first endless carrier belt to travel in a curvilinear path 6, adjacent * Registered Trademark a~

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the heating means. ~eb 7 is superimposed on said first carrier belt 3. In its broadest aspect, the present invention includes the surface of a Honeycomb type dryer as the first endless carrier belt.

According to the present invention, an open mesh belt 9 is superimposed on the web prior to heating. The open mesh structure may comprise an endless belt provided with means 11 for causing said open mesh belt to travel along an initial path 13 spaced fro~ said first endless carrier belt, and then along the curvilinear path 6 around the heating means. A second endless carrier belt 15 may be superimposed on top of the Gpen mesh structure 9. When a second endless carrier belt is used, the open mesh belt may comprise belt segments. The second endless carrier belt is provided with means 17 for causing said belt to travel along path 6. The conjugate fibers in the web, when heated, fuse to fibers in the web to provide a strong, high loft, low density fabric.
In a preferred embodiment of the method of the present invention the web is cooled before it is separated from the first carrier belt and the open mesh belt. To : facilitate cooling, the belts may be passed around at least one cooling roll shown at 19 in Figure 1. By maintaining the web between the belts until the web is cooled, the method avoids the loss in cross directional strength due to drafting as a web is removed from a roll on one carrier belt. Also the use of the two belts prevents sticking of the heated thermoplastic fibers of the web to the rolls and per~its rapid handling of the web while heated, including immediately passing the web about cooling rolls.

Figure 2 illustrates a portion of an open mesh belt 20 used in the present invention. The open areas 22 and ~ ;~37(C~

depth 24 of the open mesh belt allow the web to main-tain its high loft and low density through the heat bonding procedure. The depth 24 o~ the open mesh belt maintains the distance between the tensioned first and second carrier belts so that the web is not crushed therebetween. The depth of the open mesh belt and the degree of open area 22 determ,ine the loft of the final fabric material.
Figure 3 illustrates a fabric formed according to the method of the present invention. As shown in Figure 3A, the fabric is formed using one open mesh struc-ture as seen in Figure 2. The fabric shown generally at 30 has one surface thereof 32 which is patterned.
The surface 32 consists of regions 34 of high loft, low density and good porosity and regiGns 36 that are densified between the open mesh structure 20 and carrier belt 3. Surface 38 formed against belt 3 is smooth. The fabric has a porosity differential from the surface 32 to the opposite surface 38 and hence may be used advantageously in many applications, for instance, as a diaper facing fabric. The fabric formed according to the method of the present inven-tion exhibits a high loft, lower density and better strength than fibers formed on a double belt bonder as hereinabove referred to or with a thru-air bonder.
In the following example, samples of a web formed with a dual rotor were fusion bonded according to the methods listed.

~4 ~xample 1 PRESENT DOUBLE-THRU-AIR IMVE~TIO~`1 BELT

Weight oz/yd.~ 3.0 3.1 3.2 Bulk inch .066 .060 .042 Density gm/cm3 .0613 .0694 .1002 Tensile lb. 1.0 1.5 1.8 Tenacity lb./inch/100 grains .08 .11 .13 Absorbency % 132~ 1155 ~96 Rate sec - 3.1 3.1 9.9 Softness MD gram 135.5 133 162.7 `- CD gram 8~.1 112 162.8 As can be seen, the fabric formed according to the present invention maintains a high bulk and low density similar to that of the thru-air bonder but has a strength approxi-mately that of a double belt bonded fabric.

~'ebs used in the present invention may be prepared by air laying or carding of the fibers. The weight of the web may range from 0.3 to 5 ozs./yd.~. The present invention preferably utilizes a conjugate fiber with an outer sheath of thermoplastic material. In a most preferred embodi-ment, the fiber is capable of self-crimping when heated and the method involves heating to effect autogenous bond-ing of the web and self-crimping of the thermoplastic fibers. The web may further comprise synthetic wood pulp, wood pulp, cellulosic or other fibers. The percentage of - 30 the low shrink thermoplastic fibers in the web may vary from five to 100 percent.

The open mesh belt is preferably formed of a material with easy release properties and/or good heat transmission.
The structure of the open mesh belt may vary according to the desired properties of the fabric; the more open mesh yielding more bulk, softness and absorbency; the tighter mesh yielding higher tensile strength as set forth in the following Example.

Example 2 Mesh = 3.04.7 5.3 5.8 6.0 6.3 Weight oz/yd.2 3.13.2 3.1 3.3 3.1 3.2 sulk inch .060.062 .060 .058 .053 .056 Density gm/cm3 .0694 .06~2 .0694 .0758 .0786 .0756 Tensile MD lb. 1.51.7 1.5 l.S 1.8 1.8 Tenacity lb/ .11.12 .11 .12 .13 .13 inch/100 grains Absorbency ~ 11551219 1 1155 1070 1038 1062 Rate sec 3.12.9 3.1 4.0 3.8 4.3 Softness:
~ID gram 133162.6 132.7 143.9 154.9 152.1 CD gram 112109.5 112.4 138.6 123.1 129.7 Figure 4 illustrates another fabric formed by the method and apparatus of the present invention. As shown in Figure 4A, another open mesh belt is substituted for the first carrier belt or interposed between the first carrier belt and the web. The fabric is shown generally at 40.
Both surfaces 42 and 44 of the fabric have a surface pattern. As the surfaces 42 and 44 are formed by means of separate open mesh belts 3' and 9, they need not have the same pattern and may be formed by different open mesh belts and belts out of registry. Each of the surfaces 42 and 44 have regions 46 of high bulk and low density and good porosity and regions 48 that are densified. Though the fabrics made according to the method of the present invention~have many uses, they are particularly suited for those end uses requiring strength, bulk and absorbency.

_ . ~ _, . .. ..

Claims (6)

The embodiments of the invention in which an exclusive property or privielege is claimed are defined as follows:
1. Apparatus for heat fusing low shrink thermoplastic fibers in a nonwoven web, said apparatus comprising heating means, a first endless carrier belt and means for causing the first endless carrier belt to travel in a curvilinear path adjacent the heating means, an open mesh belt and means for causing the open mesh belt of up to 6.8 mesh/inch to travel along an initial path spaced from said first belt and then along said curvilinear path.
2. An apparatus as in claim 1 further comprising means for cooling said web and belts.
3. An apparatus as in claim 2 wherein said means for cooling comprises at least one cooling roll.
4. Apparatus for heat fusing low shrink thermoplastic fibers in a nonwoven web, said apparatus comprising at least two non-compression heated rolls, a first endless carrier belt and means for causing the first endless carrier belt to travel in a tensioned arcuate path adjacent the heated rolls, and open mesh belt of up to 6.8 mesh/inch and means for causing the open mesh belt to travel along an initial path spaced from said first belt and then along said tensioned arcuate path.
5. An apparatus as in claim 4 further comprising means for cooling said web and belts.
6. An apparatus as in claim 5 wherein said means for cooling comprises at least one cooling roll.
CA000521281A 1982-09-30 1986-10-23 Apparatus for producing a patterned belt bonded material Expired CA1237884A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000521281A CA1237884A (en) 1982-09-30 1986-10-23 Apparatus for producing a patterned belt bonded material

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US43030982A 1982-09-30 1982-09-30
US430,309 1982-09-30
CA000437830A CA1226486A (en) 1982-09-30 1983-09-28 Patterned belt bonded material and method for making the same
CA000521281A CA1237884A (en) 1982-09-30 1986-10-23 Apparatus for producing a patterned belt bonded material

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
CA000437830A Division CA1226486A (en) 1982-09-30 1983-09-28 Patterned belt bonded material and method for making the same

Publications (1)

Publication Number Publication Date
CA1237884A true CA1237884A (en) 1988-06-14

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA000521281A Expired CA1237884A (en) 1982-09-30 1986-10-23 Apparatus for producing a patterned belt bonded material

Country Status (1)

Country Link
CA (1) CA1237884A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5418045A (en) 1992-08-21 1995-05-23 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5425987A (en) 1992-08-26 1995-06-20 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

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